Join Date: Nov 2010
Location: United Kingdom
sticky clutch - solved for me
OK I've had intermittent sticky clutch problems for a couple of years on my '57 2.4 jTDM. I've followed most threads on the subject and thought a couple of times I have come across the solution. Now this is only associated with the problem of incomplete pedal return, especially the last inch of travel ie not sunk pedal to the floor. So this is what has solved it for me:
The master cylinder that the pedal operates on is located onto the pedal framework assembly by 2x10mm bolts and nuts. I find that with the pedal stuck down if I loosen the nuts and bolts the pedal immediately returns to the rest position. Looking at the assembly it is apparent that given the concentric play available between the locating bolts and the cylinder assembly it is possible that the cylinder can be firmly located onto the assembly but end up slightly out of axial alignment with the pushrod which operates the piston. I think in this situation that the piston then binds slightly in the cylinder creating additional resistance and preventing the pedal returning. The return spring is very light.
By loosening the bolts and then twisting the cylinder assembly using the free play between the holes and bolts the cylinder can be tightened up at a slightly different orientation and I have found the pedal is now returning perfectly. Hopefully for good!