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  • 2.0T 4x4 clutch issues

    Hi guys hope you are all well.
    Having a bit of a problem with the siggy at the moment. Rebuilt the engine at the start of the year and whilst it was out I changed clutch and csc.
    Once all back together I bled the clutch via pedal depress and bled valve on top of gearbox. All seemed fine but recently I have been having issues.
    The car won't go into gear whilst engine is running so I have to start it in gear. If I try to force it into first or reverse the car wants to move.
    Once going I can change gear but it's not easy. If I rev the engine a bit I can get it change easier. If I depress the clutch whilst running I can make the engine rev freely.
    Reverse, first and second gears are the hardest to engage whilst going.
    Also there is some vibration after the first inch of travel on the pedal.
    Pumping the clutch worked for a while but no longer helps. There is no loss in fluid level. Gear linkage is ok and transmission fluid is ok.
    Does anyone know the correct bleeding procedure? I'm reading different ways to do it. I want to rule out air in the system.
    Any other ideas what the issue might be?
    I'd like to avoid the box coming off but knowing my luck I know what's coming [emoji3525]

  • #2
    It certainly sounds like you have air in the system.
    I have not ever bled one of these vehicles, so I cant help on that sorry.
    LED interior lights. Chrome mirror caps & door handle covers. LED reverse light bulbs. Pedal box. Atomic Alloys. Steel Structure spare wheel. Boot floor risers. Rear exit exhaust & rear valance. M Y ‘15’ front grille.

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    • #3
      Mr iceman, the correct way to bleed the slave cylinder is to get a vacuum pump .about 10-15 pounds on that well known auction site.
      Connect it to the slave cylinder nipple , create a vacuum, then open the nipple .and observe the fluid colour and bubbles , keep an eye on the resovior.
      Once clear brake fluid comes out tighten the nipple with still a vacuum present .
      But from what you are experiencing sounds like it may be a gearbox out job if you cannot get rid of the vibration when lifting the clutch pedal .
      But let's not start panicking right now .
      Did you bleed the CSC before firing it ?
      Some say to bleed them first off .


      .K.M.P.C.U
      YEEEEEEEEHAAAAAAAAA

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      • #4
        Thanks for the replies.

        No I didn't bleed the csc but in hindsight I wish I had as any air past the slave nipple may be harder to bleed.
        I have a vacuum pump at work I will try. I did try reverse bleeding with a modified garden sprayer but didn't see no air coming up through the reservoir.
        The vibration is only after I depress the peddle about and inch and after that it's gone.
        If the car wasn't 4x4 o wouldn't mind taking the box off but with transfer box and prop it makes more of a ball ache.

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        • #5
          Hi chaps,

          Update here.

          I have bled and bled and still no luck. It's got a new clutch master cylinder as the push rod snapped [emoji853] and still no gears.
          All I can think now is clutch has failed?
          When I rebuilt the engine I used a b207r crankshaft as they are the same.
          In theory could I use a clutch and dmf kit for a Saab 9-3 as flywheel bolt pattern is the same and both use F40 gearbox?
          Saab kit is much cheaper too [emoji846]

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          • #6
            Originally posted by Iceman205 View Post
            Hi chaps,

            Update here.

            I have bled and bled and still no luck. It's got a new clutch master cylinder as the push rod snapped [emoji853] and still no gears.
            All I can think now is clutch has failed?
            When I rebuilt the engine I used a b207r crankshaft as they are the same.
            In theory could I use a clutch and dmf kit for a Saab 9-3 as flywheel bolt pattern is the same and both use F40 gearbox?
            Saab kit is much cheaper too [emoji846]
            lizzard-t is the expert on the Saab, maybe he can help.
            LED interior lights. Chrome mirror caps & door handle covers. LED reverse light bulbs. Pedal box. Atomic Alloys. Steel Structure spare wheel. Boot floor risers. Rear exit exhaust & rear valance. M Y ‘15’ front grille.

            Comment


            • #7
              I would say that would of been my therory in first place as you have used the crankshaft.
              Bolt pattern is the same .
              Oooooooo dear iceman
              Remember when you do replace to bleed the CSC before putting gearbox back in as I explained.
              10-4 rubber clubs


              .K.M.P.C.U
              YEEEEEEEEHAAAAAAAAA

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              • #8
                My only concern is clearances as it's still a lot of money and work if it's wrong.
                I've messaged the seller who is a&e Motorsport. They specialise in vauxhall and saabs so they might be able to give a definite answer.
                I don't seem to have much luck with this car [emoji19]
                Yes I will bleed the csc like you say.

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                • #9
                  MR iceman
                  So to re-cap you have no gears at all now
                  The clutch pedal is firm ?
                  Can you get gears if you pump the pedal ?
                  Can you feel the CSC throwing the pressure plate clear
                  Have you any funny noises when starting the car or using the clutch when the car is at idle ?
                  Is biting point ok ?
                  What make is the clutch you installed?
                  Did the CSC come with the kit ?
                  Have you tried vacuum bleeding the slave cylinder from its nipple ?
                  Sorry for the questions but just trying to assertain the symptoms.
                  16-24-36 rubber doll


                  .K.M.P.C.U
                  YEEEEEEEEHAAAAAAAAA

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                  • #10
                    Originally posted by lizzard-t View Post
                    MR iceman is yours 4x4 ?
                    So to re-cap you have no gears at all now
                    The clutch pedal is firm ?
                    Can you get gears if you pump the pedal ?
                    Can you feel the CSC throwing the pressure plate clear
                    Have you any funny noises when starting the car or using the clutch when the car is at idle ?
                    Is biting point ok ?
                    What make is the clutch you installed?
                    Did the CSC come with the kit ?
                    Have you tried vacuum bleeding the slave cylinder from its nipple ?
                    Sorry for the questions but just trying to assertain the symptoms.
                    16-24-36 rubber doll
                    Yeah mine is 4x4.
                    No gears at idle, can start in gear and change by matching engine speed.
                    Clutch pedal is firm.
                    Pumping pedal makes no difference.
                    Not sure how that should feel but I did make an inspection hole on top and can see the csc pushing against the pressure plate but hard to see if it's going all the way.
                    No funny noises to report, just slight vibration on pedal at about an inch of travel.
                    No biting point. When started in 1st car will lunge forward with clutch pedal depressed into the road, clutch isn't disengaging. However when driving, if the clutch pedal is where the biting point should be and I apply throttle the clutch slips.
                    Clutch is Borg & Beck, csc didn't come with it. Csc is GM.
                    Yeah I tried vacuum bleeding at nipple, no improvement.
                    All I can say is that it has got worse from when I first had an issue as originally I could change gear by pumping pedal. Biting point was quite low. I don't have any leaks and haven't had to top up fluid.

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                    • #11
                      From what you have explained sounds to me like the clutch unit itself is goosed .
                      10-4 rubber gloves


                      .K.M.P.C.U
                      YEEEEEEEEHAAAAAAAAA

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                      • #12
                        I may have damaged the pilot bearing when installing the engine as it was tight when going back. May have caused some misalignment and eventually clutch has failed. Thanks for your help lizzard-t

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                        • #13
                          So I've had a bit of luck with parts. Managed to order a GM dmf from neo brothers for 150 and also a GM clutch for 100 from eBay, both brand new I might add.
                          Going to order some flywheel bolts and pressure plate bolts and few other bits from ZZP out in the states. Even with shipping and taxes it seems to work out cheaper.
                          I won't lie I'm not looking forward to to the job as there is a lot to move (exhaust, propshaft, transfer box and sub frame) just to allow the geatbox to come out.
                          I'm looking at changing the catted downpipe as I can only get this out whilst the transfer box is out the way but I'll start another thread as I have a few questions.
                          Got a week booked off soon so going to have a crack at the siggy then.

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                          • #14
                            Hope it turns out ok for you.
                            LED interior lights. Chrome mirror caps & door handle covers. LED reverse light bulbs. Pedal box. Atomic Alloys. Steel Structure spare wheel. Boot floor risers. Rear exit exhaust & rear valance. M Y ‘15’ front grille.

                            Comment


                            • #15
                              I've always trusted NEObrothers for my Saab parts and that's a damm good price on the DMF .
                              Just keep us up to speed MR Iceman Sir .
                              It must be really disheartening knowing you are doing the job again through no fault of your own .
                              I'll be really interested to find out what the issue is !
                              10-4 rubber clubs


                              .K.M.P.C.U
                              YEEEEEEEEHAAAAAAAAA

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