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Old 08-18-2003, 05:46 PM   #1
tmat3
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Default The free-play on my clutch keeps on changing!

Hi,

I changed my clutch last month by myself. I installed a new pressure plate, disc, throw-out bearing, and bearing clips. All of them are OEM parts. Well, 1500 miles later, I'm starting to find that my clutch changes its free-play. When I'm driving on highway or when I first start the car, there is only about 1/2in of play. I think that's normal.

But, when I start driving in a city traffic with a lot of stop-and-go driving, I get more free-play eventually. And, the clutch engagement point is a lot lower to the floor.

There is no problem with shifting or driving operation. No grinding gears, no slipping clutch, etc etc.. But, it's really annoying and it's not really supposed to do that. I bled the clutch hydralic system, but it didn't solve the problem.

What do you think the problem is????? Any help is appreciated. Thanks!
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Old 08-18-2003, 07:25 PM   #2
goobie
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Default Slave Cylinder

Consider changing your slave cylinder and clutch line. There's a couple of treads about the TSB for this problem.

Chad
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Old 08-19-2003, 11:13 AM   #3
tmat3
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Default

After searching for this TSB, it does look like I need a new slave cylinder and a new line. But, why did it fail all of a sudden!? Before chaning the clutch, I didn't notice this problem.
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Old 08-19-2003, 02:34 PM   #4
goobie
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Default Slave Cyl

Quote:
After searching for this TSB, it does look like I need a new slave cylinder and a new line. But, why did it fail all of a sudden!? Before chaning the clutch, I didn't notice this problem.
Yeah, I'm not suprised... I've had to replace mine twice now. The first time was (ironically) after a clutch change and the second time it was just a progressive deterioration, up until the point where it started to affect my shifiting ability.

So I've had one go suddenly and another go progressively... I really can't say why other than they just plain 'ol suck!
They are subjected to quite a bit of heat though, being bolted down to the block like that. I'm guessing the heat breaks down the rubber seal inside over time and eventually starts to let fluid and dirt bypass.

Chad
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Old 08-21-2003, 02:51 AM   #5
Blu25RS02
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Default

I'm actually having the same problem on my RS. How expensive are these and how hard is it to do as in can I do it myself? Im sure both tmat3 and I would greatly appreciate it.

Patrick
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Old 08-21-2003, 06:45 AM   #6
tmat3
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I did a search, and it looks like the slave cylinder + line + gaskets = $80 or $100. Installation should be as easy as changing a brake caliper.
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Old 08-21-2003, 09:46 AM   #7
goobie
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Changing the slave and line is not difficult. I can be done in about 20-30 minutes. One thing you may encounter when trying to remove the line is that things are difficult to get at and the small nut on the hard line is really soft and easily stripable (is that even a word??) I found it much easier and safer to remove the whole braket and hardline assembly from the car and separate the rubber line on the bench to prevent buggering-up the nut. In order to do this the hardline will have to disconected from the master cylinder which is much easier to get at then the other end of the hardline. Make sure you keep everything clean and keep dirt from getting into the system. You should also use new gaskets (they look like regular washers) on the banjo fitting to the slave. They cost next to nothing...

I think if you look at the instructions on how to install an SS clutch line on www.scoobymods.com you can see what I'm talking about.

The trickiest and most important part of the job is to ensure the system is bled properly. Again I believe the kind folks at Scoobymods.com give instructions on how to do this. Since you have to change the fluid anyway, spend the extra couple of bucks and get a high quality fluid like Motul or at least a DOT 4 synthetic. I put Valvoline DOT 4 synth in mine and the peddle has been rock hard even on the hottest days...

Cheers and Good luck!

Chad
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Old 08-21-2003, 10:38 PM   #8
Flexy
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I been having same problems on hot days.
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Old 08-21-2003, 11:51 PM   #9
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I had this problem on a Toyota. It was a bad fork AND a loose Cleavis on the clutch pedal.
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Old 08-22-2003, 12:30 PM   #10
tmat3
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Ok, I just came back from the Subaru dealer and ordered a new slave cylinder, new line, and 2 gaskets just like the TSB says. I'm well out of the warranty period. They had no clue that there was a TSB on this issue. Anyway, I hope those new parts would fix my problems. The whole thing was $110 including tax (VT sales tax).
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Old 08-22-2003, 12:45 PM   #11
Flexy
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Let us know if it fixed the problem. Also do you have instructions on how to change it?
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