I just swapped my 1.5 with a built a6/z6. The original motor had 385k on it, the started **** the bed when we tried to start the new motor so i put another started in and it started up fine. I put a new spec stage 4 clutch in along with a new throwout bearing and such.

I tried to bleed the clutch and no fluid would come through the slave cylinder but would would come out when i disconnected the line before the slave cylinder so i took an air hose and put some air through it thinking it was clogged or something and it worked. Then i finally bled the rabkes and took it for a ride to warm it up to set the timing. When i came back i set the timing and then went to take it for another ride and it wouldnt go into gear. I used a gravity bleeder to bleed the brakes 3 or 4 more times and there is no air in the lines that i can tell.

The piston in the slave cylinder only moves 7/16" and i was told it should move
1 1/2 inches or so. If i pump the brakes a lot i can get it into a gear but it crunches going in and it will only go in 1 time. From what i can tell the brake fluid in the clutch master cylinder isnt going down. I think i need a new slave cylinder. What do you guys think? Thanks in advance.

 

TTT

 

I don't know about '92, but my '95 slave piston moves about 12mm. So your 7/16" is about right.

After blowing air thru the slave, then you could bleed it properly? Or does it still not bleed? If it doesn't, then I'd say you need a new slave.

Maybe the clutch is warped or something, making it drag even though the hydraulics are OK?

 

Well i bled it and bled it and it didnt change anything, there was no air in the lines. Then for ***** and giggles i pushed in the clutch pedal half way and tried to shift gears and it would shift gears as smooth as before but as soon as you put the pedal all the way to the ground it wouldnt go into gear, it would even go into gear if you held the clutch 1/4 of an inch off the ground but as soon as you pushed it in all the way it wouldnt go.

So i looked under the dash and noticed that i could make an adjustment on the clutch pedal so i gave that a shot, i backed the nut off so that the clutch pedal would sit about an inch lower thinking that with the clutch pushed all the way in it would be like it was before with the clutch only pushed in half way and sure enough it worked. Anyone else ever have to do this? i dont know if it is because the pressure plate is too stiff for the fork to push in or what but i have never seen or heard of anyone having to do that. What do you guys think?

 

Now is the pedal height adjusted correctly? Or did you have to make it 'too low' in order to work?

I would've had you check this before adjusting it, but maybe you already noticed...

Have someone press down the clutch pedal slowly while you watch the slave piston. Does it keep pushing out or does it go back in during the last part of the pedal stroke? It should keep pushing out as the pedal goes down.

If it keeps going out, then there's something wrong with your pressure plate. Somehow it engages the clutch again when it's pressed in all the way. Keep an eye on it; adjusting the pedal probably isn't a permanent fix.