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Help! Changed clutch but now pedal is floppy

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2000, C4 Cab

Help! I was just patting myself on the back after getting the transmission back in and only had the sway bar and wheels to refit. Decided to check the clutch felt right and unfortunately it doesn't. The pedal is really soft and the clutch doesnt disengage.

I didn't open any hydraulic lines but could this just be air? Or do I need to drop the transmission again to check what's wrong inside?

If I take the slave cycliner off can I gently press the clutch pedal to see if it drives the slave?

As far as I can tell everything went back together OK so I'm stuck...

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  • Moderators

It may also be that the slave cylinder push rod is not in the correct position of the fork, anyway, this is only visible after removing the slave cylinder.

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  • 4 weeks later...

Dropping the transaxle was not all that difficult. I made up an engine support from some heavy aluminium channel I had. All four of the bolts holding the sway bar (anti roll bar) to the rear subframes sheared and drilling them out took a lot of patience. I disconnected the drive shafts at the flanges. I'm not sure if that's the recommended way but it was simple enough. I supported the transaxle on a floor jack with timber blocks to lift it high enough. Mines a C4 so I had to dissconnect and remove the drive shaft to the front wheels as well. The support bracket for the front of the transaxle wouldn't come off over the drive flange so it stayed there loose until the transaxle was most of the way out. I was able to reach all of the bell housing bolts with a mixture of 1/2" and 3/8" drive sockets and for the one at the top a combination spanner. Depending on the year you need the right size spline bit for one of the bolts.

I've lowered a couple of gearboxed before by basically lying under the box and letting it rest on my chest then kind of rolling it off. DON'T try this with the Carrera as the transaxle is really heavy!

I used two floor jacks, some levers and lots of timber blocks. A transmission jack might have made things easier but then I'd have needed the car up higher which would make getting at the bell housing bolts more difficult.

The problem I had meant that I had to drop the transaxle trwice. Second time was really straight forward, about 2 hours down and 2 hours back up.

I hate to admit it but I had put the clutch plate in backwards! I think the thing with the engine at the wrong end of the car threw me off!

All back together now and going fine.

Made my first attempt at a donut the other day and the new clutch worked a treat!

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