Clutch has no resistance

[mtnbob]

I hooked up the clutch, shifter linkage, and cv joints. When I went to start the car, I realized that I had almost no resistance from the clutch pedal. After you put on a new clutch, is it very easy to push, or did I screw something else up? The arm on the transmission moves pretty easily, much easier than before. Any ideas what I might have missed?
TY

[mtnbob]

Any ideas?

[theman53]

did you put the pushrod in?

[mtnbob]

I hope so. Will check after dinner

[mtnbob]

Maybe a dumb question, but is it possible for the clutch to be stuck in some way? maybe when I put it together, that it isn't pushing back on the pushrod?

[mtnbob]

I took off the end cap to find that the throwout bearing and pushrod were installed correctly So this probably means deeper problems. There is no pushback from the throwout bearing and pushrod at all 

When I put on the release plate, was it supposed to fit into the indentions of the clutch pressure plate?

[R.O.R-2.0]

I took off the end cap to find that the throwout bearing and pushrod were installed correctly So this probably means deeper problems. There is no pushback from the throwout bearing and pushrod at all 

When I put on the release plate, was it supposed to fit into the indentions of the clutch pressure plate?

the clutch push plate only goes on the right way.. you can not assemble that plate wrong..

your push rod might be the wrong length..

or else your clutch throw out finger is broken.. they LOVE to break..

[8v-of-fury]

Your having all sorts of issues aren't ya? Gotta slow down before you set something on fire and loose it all! lol

I have a suggestion to make, Google search ETKA 2007 and find a torrent to download.. One of your sons will be able to help out no problem, it helps SO much.

So looking at this blow-apart from my ETKA;) it shows us how everything should go together. Not really possible to screw up the clutch and have it even go together to begin with. Sure you could have put the pushrod in backwards, but it wouldnt hinder clutch operation. Does the pedal go to the floor? Did you start the car with it in gear and the clutch to the floor? Or are you a neutral starter no clutch like myself lol? Did  the clutch work at all?

[Dakotakid]

How about item #14 on the above diagram?

Did you inspect it prior to assemble to ensure the center "button" was in good shape and not totally worn out or even already "holed?"


Getting holed always causes problems...........

[mtnbob]

Ok first of all I'm not that old(47) that I'm not well acquainted with torrent files.  I have two Bentley books I have been following. This is my first try at something this ambitious!!

I started the car the first time without the cv axles attached to see if I could start the engine first.

I then attached the cv axles and put the car in neutral and started it again.

I pushed on the clutch pedal and instantly noticed almost no resistance.

The pushrod was from my transmission from the 1.6 N/A. Would a different engine(1.6 TD) use a different pushrod length??  The arm seems to be working properly, it just seems like the release bearing is in there too far and I can only get it out with a magnet. Should I be able to push on the release bearing with something to tell if it is engaging at all, or is it take too much force to do that?

[8v-of-fury]

Good point, I figured he did a new clutch it was probably replaced.

[mtnbob]

The release plate was fine

[8v-of-fury]

LOL I AM SORRY! I only assumed.. well that you were old.. lol my bad

There is no way you will push the realease bearing in by hand, ever. Also I bet there isn't a man among us VW guys who could lift up on the clutch arm enough to actuate the clutch at all.  It is a strong spring on that pressure plate, the pedal shouldn't be hard, after all it was only a stock clutch right? Should be super easy.

[mtnbob]

So what is up with pushrod length? The Bentley mentioned nothing that I saw about different lengths of rods. I'm going to take a closer look at the arm. But it did work perfectly when I used it last a month ago, so I am back to examine again!

[8v-of-fury]

4spd is one length, 5spd is another. Only two lengths.