This topic has been posted on before on the NASIOC board, but it's been awhile and, since I haven't been able to resolve the issue for my car (MY98 2.5RS), I thought I'd resurrect it here and see if there are any new ideas out there.

Basically the feel of the clutch pedal varies from having a fairly strong return to having a very weak return (almost no resistance to being pushed down). It's as if there's a strong return spring which gets disconnected sometimes! When there's little resistance in the pedal, the clutch doesn't seem to engage with as much "authority" and the actual engagement point changes as well.

The problem seems more severe in hot weather, but also when I'm using the clutch alot (stop and go around town), regardless of the outside temperature.

This is what has been done so far:

1. The complete clutch, flywheel etc. has been replaced 4 times (under warranty ).

2. The master cylinder and slave cylinder has been replaced once (under warranty ).

3. Obviously the hydraulic fluid was replaced each time (1and 2) and, in addition, I've flushed the system twice. The last time, about 3 months ago, I replaced the fluid with Motul 600 high temperature racing fluid.

4. The fork which attaches to the slave cylinder at one end and contacts the clutch release bearing at the other has been lubed.

5. The flexible hose part of the hydraulic line has been replaced with an upgraded braided stainless/teflon one.

NOBODY has been able to figure this one out!

Any ideas are very welcome! Thanks!

John

 

is the clutch fork pivot binding??

 

Hmmm...don't know. I'll check it out. Thanks for the suggestion.

 

check out TSB 035203 that might help

 

Hahah, wtf is that?

jason