ajh Posted June 4, 2015 Share Posted June 4, 2015 So I had a valeo HD clutch installed and the friction disc came apart (rivet failure) so I swapped in a LUK friction disc that looked identical in thickness.... now without changing anything else at all it is behaving like the pushrod is too short. At best the clutch slips with the pedal fully depressed... Ideas? Quote Link to comment Share on other sites More sharing options...
Les Henson Posted June 4, 2015 Share Posted June 4, 2015 Are you certain that the plate is the right way round?, this can make a significant difference. Small variations in plate thickness make little difference on mechanical or hydraulic systems, as that is pretty-much compensated for either automatically with a hydraulic system or adjustment on a mechanical system. LUK clutches are OE spec, and are good quality. I wouldn't recommend just changing the plate though. Les Quote Link to comment Share on other sites More sharing options...
ajh Posted June 5, 2015 Author Share Posted June 5, 2015 It is what I had... it is installed correctly; this is the 4th in this vehicle.. I've tried adjusting the pedal box, as well as changing to a slightly different slave cylinder... I guess the master is the only real thing left. Quote Link to comment Share on other sites More sharing options...
Maverik Posted June 5, 2015 Share Posted June 5, 2015 I tried fitting a friction plate the wrong way and you can't, the boss fowls on summet and just looks very wrong. Try the master cylinder change, that and the rubber flexi hose near the slave can starts to balloon which could cause symptoms like you've said... Quote Link to comment Share on other sites More sharing options...
Pepé le Pew Posted June 5, 2015 Share Posted June 5, 2015 The slave is self adjusting but if you fitted a new friction plate the piston is still set at the old situation. It usually takes a couple of drives for the piston to adjust to the new situation. Eric Quote Link to comment Share on other sites More sharing options...
Eightpot Posted June 5, 2015 Share Posted June 5, 2015 Air bubbles in the system will do this too, though doesn't sound like you've interfered with the fluid - as said above it sometimes takes a little while for the plate/slave to settle Quote Link to comment Share on other sites More sharing options...
ajh Posted June 5, 2015 Author Share Posted June 5, 2015 I rebuilt the pedal box to remove the small amount of slop I was feeling but when re-fitting I noticed the screw that in the diagrams is for 'pedal height' on mine is nearly at the bulkhead and above the first pivot so has zero affect on pedal height... is this a different type of pedal box that I can't find the directions for? The screw seems to be a stop for maximum pedal depression and not resting height as it touches the pedal arm just above the assist spring... Quote Link to comment Share on other sites More sharing options...
ajh Posted June 8, 2015 Author Share Posted June 8, 2015 Well, looks like it's the master... obvious wear on the piston and seal.. I'm close to just machining my own replacement unit. There's got to be a better way to do these; not every vehicle has them failing this often. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted June 8, 2015 Share Posted June 8, 2015 The annotation of the drawing is wrong, that is indeed the pedal stop. I set the 140mm pedal height with one nut on the push rod, the other nut sets the 1/4 inch of free play. In reality there is enough play in the clutch pedal pivot assembly to cover the play so the free play nut usually ends up run right up to the trunnion. HTH Mo Quote Link to comment Share on other sites More sharing options...
ajh Posted June 8, 2015 Author Share Posted June 8, 2015 I just added a pedal height screw when it was out; easy enough. Quote Link to comment Share on other sites More sharing options...
Maverik Posted June 9, 2015 Share Posted June 9, 2015 The quality of clutch and brake parts is pretty poor, even for Genuine units in my opinion, I've lost count of how many brake and clutch master cylinders I've changed out. Quote Link to comment Share on other sites More sharing options...
cackshifter Posted June 10, 2015 Share Posted June 10, 2015 I think you can get them stainless lined - it's an Aussie thing but they are available in certain other countries - that has to be pretty much a one time fix? Quote Link to comment Share on other sites More sharing options...
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