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Can anyone help me please - boring content 2003 VW Caddy SDI
The biting point has been steadily getting lower but now it's somewhere under the floor pan... I can't fully disengage the clutch. This has been particularly bad over the last few days, now with the added difficulty that the clutch pedal doesn't like to return. Maybe 25% of the time (and rising) it sticks down/halfway down.
Are the two problems related? What should I be looking for? I've never done anything with clutches so don't know exactly where to start. The brake fluid reservoir is full and I can't see any fluid leaks. What to look for next?
Any help much appreciated, it's a right faff driving around town at the moment
Thanks
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Last Edit: Dec 7, 2016 23:55:50 GMT by wichard
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if its hydrulic try bleeding it , chances are its the master or slave starting to go
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91 golf g60, 89 golf 16v , 88 polo breadvan
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Dual mass flywheel replacement cured same problem on ours at work after the clutch slave and clutch master cylinders being replaced didn't help
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The problem is now accompanied by some horrendous noises. Over a few miles it's gone from a low groan to a low groan + lots of whizzing and clicking noises like something stuck in the spokes of a bike wheel. Pressing the clutch takes away most of the noise. I have a feeling this is related to something I asked about before (please see this thread retrorides.proboards.com/thread/190307/seized-engine-why). Could it be true that some part of the clutch assembly has broken off, initially seized the gearbox but is now whizzing around merrily? I'm not sure how this would affect the clutch pedal returning but maybe that's a coincidence. |
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Last Edit: Dec 8, 2016 23:02:42 GMT by wichard
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you need a new clutch pack.
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Needs a bigger hammer mate.......
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Gearbox out. Springs from drivenplate could have hammered their way out and parted company.
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bortaf
Posted a lot
Posts: 4,549
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If it was a ford i'd say the 3 springs that attach the drive plate to the cover have broken? not sure on a VW but it could be the issue ?
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R.I.P photobucket
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Dec 14, 2016 23:56:48 GMT
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Ok new development. Last night I tried to drive it round to my garage (few hundred metres). Made awful noises all the way and then completely lost drive at the crucial moment when I was trying to manoeuvre it inside. The engine was still running at this point but I killed it when it was obviously going nowhere. Once I eventually got it inside I tried to start engine again but now no luck. Starter turns fine but there's just a dreadful metal on metal noise.
Could the flywheel or clutch have come off completely now? I found 3 small sheared off metal studs/bolts under the van after I got it inside which I'm sure weren't on the floor beforehand. I'm obviously worried these were holding on something important but not really sure how they got outside of the bellhousing. Will try and get a pic of them tomorrow as they are not just normal bolts (round head, shoulder, small threaded section which is snapped)
Thanks all for the help so far, I guess I'll start getting the gearbox out tomorrow
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Last Edit: Dec 15, 2016 0:17:41 GMT by wichard
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froggy
Posted a lot
Posts: 1,099
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I'd be looking at the n/s driveshaft bolts snapped . Seen it many times where the inner lobro joint bolts to the gearbox flange
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Last Edit: Dec 18, 2016 2:41:47 GMT by wichard
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blower
Part of things
Never mix Cider and Red Wine , Thats 1 of my Life Lessons . J.C.
Posts: 252
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Looks to me like the dual mass flywheel has caused the problems , horrible things...
Probably been loads of play till the bolts had to give
Is there a solid version you can buy , i know the transit can be swapped out
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Dec 18, 2016 19:16:23 GMT
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Exactly what ours did ðŸ˜
Had it fixed and the engine vandalised itself to death less than 10 000 miles later. Wether it was related to the dual mass flywheel flywheel failure is debatable
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Dec 18, 2016 19:46:13 GMT
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Past owner went the traveller route and replaced the friction plate and not the DMF and/or re-used bolts. Like I said you need a new clutch pack.
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Needs a bigger hammer mate.......
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I've bought a new valeo clutch kit. Hoping I can get away with keeping the flywheel - what do you think? Looks ok to me
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Rich
Club Retro Rides Member
Posts: 6,325 
Club RR Member Number: 160
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I've bought a new valeo clutch kit. Hoping I can get away with keeping the flywheel - what do you think? Looks ok to me 'Looks OK' or 'I followed the documented test procedure to see if I need to replace'? How far can it be turned before it encounters resistance? Is the centre plate 'loose-feeling'? Chances are it needs a new DMF and clutch.. |
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Dec 24, 2016 18:13:48 GMT
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Ok maybe someone can set me straight here as this is the first time I've changed a clutch - but are you all sure this is a dual mass flywheel? I was under the impression there would be 2 parts damped by springs but as far as I can see the flywheel is just one bit of solid steel. The only springs are on the clutch friction disk (which would suggest it's a solid flywheel). The only damage I can see to the flywheel itself are some marks from the broken bolt that was rattling around in there. The bit that mates to the clutch disk is fine, as are the teeth for the starter (hence me saying it looks ok). The only actual broken parts I can see are the fasteners that connect the flywheel to the pressure plate (correct name? - the bit that is still bolted to the engine in the photos above). Obviously I'm replacing these. Apologies if I'm being dense (I'm not familiar with these parts at all) but I've received a new clutch kit and the only part that isn't included in there is the solid steel disk with the teeth around it - so I can only conclude that is the flywheel and it's a one piece part. I googled around trying to order a replacement and the results look the same as what I already have (eg www.ebay.co.uk/itm/VW-CADDY-VAN-1-9-SDI-2001-AYQ-FLYWHEEL-/152185043339?hash=item236eef798b:g:SKkAAOSwRoxXmk3o) so I assume this is how it left the factory. I really would like to put a new flywheel on for peace of mind but I would also really like to get it fixed asap rather than waiting a couple of weeks for a replacement to arrive. What do you think - is it a DMF or SMF? Can I reuse the existing flywheel? Any other pointers? Thanks all for your help |
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Last Edit: Dec 24, 2016 18:14:21 GMT by wichard
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Dec 24, 2016 18:47:56 GMT
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That looks like the VW back to front clutch and is single mass as the friction plate has springs in it. These are the reverse of how normal clutch and flywheel are as you have to take the flywheel off to replace the clutch.
As it looks like the flywheel bolts sheered off and the flywheel came off I'd be checking the mounting plate on the end of the crank for being true either before mounting the flywheel and clutch or after if it is easier then with a dial gauge or similar to make sure it is still all turning true. I'd also have a careful look at the threads on that mounting plate for damage.
Edit: but on 2nd thoughts that is probably the remains of the pressure plate and will be replaced...
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Last Edit: Dec 24, 2016 19:07:07 GMT by sausage
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Dec 24, 2016 18:53:04 GMT
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Yeah I did wonder why the flywheel wasn't bolted to the crank. Wasn't easy getting that pressure plate off without any obvious way to lock it.
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Dec 24, 2016 19:11:43 GMT
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Impact gun is the easiest way for removing them.
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