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Old 09-19-2014, 05:21 PM   #1
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Odd new clutch issue

I replaced my clutch, master cylinder, slave and all the clutch bits. The clutch had been hanging up and not always releasing when the pedal went down (it was really bad when the car was cold - to the point of having to start the car in gear), the MC was leaking and the whole thing had over 100,000 mile on it.

New clutch works great, good feel, very light and responsive everything about feels new, as it should. Then we had a morning with a temperature in the low 40s and I had no clutch. Had to start the car in gear and until the car warmed up I had to pump the pedal numerous times to get it to release even a little. Works great when it warms up and now that our mornings are back in the 50s no more trouble.

Does anyone have any idea what could be wrong?


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Old 09-19-2014, 06:13 PM   #2
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Something's not adding up. Starting in gear with a clutch that won't release you'd be moving down the road as soon as the engine fired.

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Old 09-19-2014, 08:10 PM   #3
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That is what happens. I have to start the car in gear because with the engine turning I can't put the car gear with the engine running because everything is spinning. Very weid to have it happen only when pretty cold.
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Old 09-19-2014, 08:50 PM   #4
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Excuse a question that may not apply.

Have you tried putting it in another gear before trying to get into first/reverse when cold?

This is often necessary in colder weather even when all is working normally, to slow down the gears spinning more than usual because of the thicker oil.

I've had a hydraulic clutch issue once in the cold, but it was an old car & extreme cold.
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Old 09-20-2014, 10:08 AM   #5
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I'll have try that the next time it gets cold, but even once I get moving it is tough to get into any gear for a couple of miles until stuff warms up. Might get cold enough next week to try it out.
Need to get this figure out before winter.
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Old 09-20-2014, 07:54 PM   #6
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Shouldn't be TOO stiff unless very cold. The getting into first/reverse procedure of trying another gear first can help at ANY temperature when at a stop.

What kind of transmission fluid did you use when changing the clutch?
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Old 09-21-2014, 05:08 PM   #7
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Had a little chance to play with this in the morning. The clutch is clearly not disengaging when the temperature drops. It is not the gears in the transmission being stiff. It gets a little better by pumping the pedal a lot but when warm it works just fine.
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Old 09-22-2014, 05:20 AM   #8
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It is likely the hydraulic system, when it's cold the metal of one of the pistons is contracting to the point you lose seal. Since you have no leaking fluid I would guess the master cylinder. If you haven't tossed your old master cylinder you could clean it up and swap it back and test.
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Old 09-22-2014, 02:07 PM   #9
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We will try that. Hopefully it is not the slave cylinder causing the issue.
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Old 09-22-2014, 04:01 PM   #10
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How does the pedal feel on a cool morning?

Unless it goes part way to the floor without resistance changing the master won't help.

Saw another today that had a problem with clutch return spring, that can drop the pedal after sitting. I'll link that in a sec. http://www.focusfanatics.com/forum/showthread.php?t=480985

Still wondering what trans. oil was used for the refill when the clutch replacement was done...
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