My95 Sti ra no clutch pedal pressure after recentgearbox rebuild including clutch etc
 

Had a recent gearbox refurbishment including new clutch and flywheel, work was done by a very respected specialist three months ago covering only 500 miles,

Took the car out today in the glorious weather, was out for half an hour when changing from 3rd to 4th the clutch pedal remained to the footwell, managed to get the pedal back up with my foot still being able to change gears,

Thought I should make my way home when changing through the same gears the clutch pedal remained in the footwell with absolutely no pressure whatsever and know even if I lightly touch it, the pedal goes straight to the floor!!

This made for a difficult journey home with no clutch,

Checked the fluid level, all ok and no leaks,

Has anyone experienced this,
Wonder if it's a related problem with the work that was carried out,
Doesn't seem like it would need to bled

Any help would be greatly appreciated

Regards

1st thing to check is that the clutch fork/bearing are still engaged in the cover plate and the end of the cylinder is pressing on the fork. If you cant move the fork with your hand then its likely you have a knackered master cylinder.

Cheers for the quick reply, would this be anything related with the work I had done or is it just one of those things, can what your suggesting be done without the transmission out,

you can see the fork and clutch cylinder under the intercooler on the passenger side.

The end of the cylinder extends out to push the fork. If the end is not located against the fork you'll get a dead pedal so 1st check that its behind the fork but NOT in the hole at the top, if it is then check that you cant move the fork forwards toward the front of the car by hand. If its solid, and the cylinder is lined up then you either have air in the system or a knackered cylinder

Thanks for all the help and info, will take a look and hopefully find the issue
Regards

See the picture typer99 uploaded, the fork has a small spring! I had this fail on me & lost the clutch all of a sudden with no warning, a common problem. If the spring isn't there then I'd start with that, hopefully so as is a easy & cheap fix

Cool, thanks for the reply, by the advice you've all given me doesn't sound so serious so fingers crossed

Right guys had the intercooler off, looks slightly different in configuration but mainly the same thing, everything seems pretty solid and doesn't seem to be any spring but not saying there should definitely be one as does seem slightly different
Here are a couple of pics, hope you can help
Attachment 42862
Attachment 42863

Just to add, does seem to be missing a spring at the top of the fork as found what seems to be the base plate with locating hole further back in the engine compartment, besides this, still can't push the fork back and is solid
Regards

Looks like the slave cylinder is to far out. Have seen the adjustment on the peddle adjusted up after a new clutch and then (sometimes) it pops the slave cylinder out to far when pressed. See can you encourage the piston back in if its tight.

As said, the slave is extended all the way out, so its stuck and means the clutch is disengaged. looks like it needs a new clutch cylinder.

or the release bearing has came unclipped from the pressure clip or the retaining clip is broke

since he has drive and pedal is on the floor i would say the release bearing is out of its clip and if doesnt clip in its a gearbox out job to new the clutch

Spoke to the specialist this morning and they would rather have it collected to properly inspect it, the only problem being that if they collect it and find out that it's not related to the work they have done, I.e slave cylinder I will end up with a big bill for collection as their not exactly local. So the new question is do I just start changing parts and see if that rectifies the issue or have them collect it

Dude, the cylinder is 2x 12mm bolts and a couple of 10mm spanner fittings. Its the sort of job that takes 30 mins with basic tools. You can get a new cylinder from Import Car Parts and you'll need a small bottle of clutch/brake fluid, a small bore bit of pipe for bleeding and thats it.

Yeah that's what I'm going to do on the weekend and go from there, thanks for all the help

Will keep all interested parties updated once done
Regards

Look at the clutch arm

It's all the way forward and the slave piston is fully extended

That tells me the release bearing isn't clipped into the clutch plate or the release bearing isn't clipped into the clutch fork

If fully forward and release bearing is clipped in then he would have no drive

Hopefully not, will eliminate the clutch cylinder etc on the weekend and if no joy, specialist who did the work will have to collect the car up
Regards

before doing anything

take slave off gearbox
take dust cover off and look down the hole with a torch or take picture with camera phone with flash to see if release beraring is attatched to clutch or clutch fork is doing nothing

Will do, cheers

Right guys not good news,

Took the slave cylinder off and instantly relieved the pressure on the clutch fork,
However the clutch fork is flopping around and travels too far back and there is no pressure on the clutch pedal and just flings down into the footwell and stays there so looks like something is amiss within the gearbox etc.

I changed the slave cylinder anyway for good measure along with return spring,

Looks like the problem lies with the specialist as I've only covered 600 miles since the work was completed,

Below are a few updated pics, look forward to any input
Regards

Attachment 42464

Attachment 42465

Looks like the release bearing is broke

Gearbox out job

Would it be safe to say then that this is a direct problem with the work that was carried out or pure coincidence, want to get my facts together before ringing the specialist on monday

Definately sounds like the release bearing has popped out. I'd imagine the specialist reused the old one when putting it back together and it's maybe a little worn.

Have you tried popping it back in ??
If the bearing is still on the fork you can force the fork back towards the back of the car, this should pop it back in. Be sure to press the fork back hard and fast though.
If that doesn't work try and peel the rubber boot up that sits around the fork. Then use a torch to peer inside, you should be able to see what going on. Then maybe manipulate the bearing back into position with a couple of screwdrivers.
If this all fails then it is indeed gearbox out job. Be sure to use a new release bearing next time :thumb:

The specialist won't take responsibility for this problem I can assure you of that though.

Ok cool will try that tomorrow,
This was my concern with the specialist being so far away ending up with a big bill for something that could of been sorted at the time or prevented,
A bit frustrating considering the minimal amount of mileage covered since the work was done

take the cylinder off and push the top of the fork towards the bulkhead as far as it will go. You should hear a click as the bearing locates. Problem is, its a pretty basic fitting, theres a spring clip in the centre of the clutch plate held on with a circular wire clip. If the bearing pops out its usually because the wire clip was poorly fitted and has pinged off.
If its come off then the bearing wont hold in the plate no matter how hard you try and its an engine out or box off job.

This image shows the bearing (bottom) then the spring clip and wire clip. When changing a clutch you have to take the clip off to release the bearing from the cover, put the spring clip in the new clutch cover with the wire clip on. You then put the bearing on the fork and engage it once the engine/box are back together

Attachment 42461

Well have to say I'm quite disappointed with the specialist, used them in the first place because of their reputation even though they were far afield,
Rang them this morning explaining what was wrong and what I had changed etc, there solution was to pick the car up, assess the problem and give me a quote, I wasn't expecting them to claim liability for the problem but was half expecting them to say we will have a look and if it is something that's been done our end won't incur a change,
Vented my disappointment saying that it can't be no coincidence that the problem has happened after only covering a few hundred miles after the work was done, was told that I would get a phone call today from the gearbox mechanic which never happened so a bit unhappy,
Very frustrated as spent a lot of money with them and what seems to be a problem that could of been prevented either with minimal cost or more thorough workmanship is annoying,
So don't know wether to bother ringing them again tomorrow or get it collected and taken somewhere more local buy not necessarily a Subaru specialist,

Have you tried the things I mentioned above ???