S4 clutch issue, no start

[DonPistachio]

Hello all, I seen that this issue has come up in previous threads. Hoping some recent advise has been posted. So I just replaced my motor, installed new motor mounts, and replaced the clutch while doing swap. I just purchased South Bend stage 2 friction disc and pressure plate, and aluminum ECS flywheel. This was the kit on sale over the holidays at ECS. Installed clutch while the engine was out, and trans still in vehicle. Also removed slave cylinder out, before installing clutch. Furthermore, changed clutch line to steel braided line. Bled clutch. Car all back together, fired up no problem. Bled coolant, top everything up..etc. Car ran smooth throughout bleeding. While parked, clutch pedal smooth, when through gears. Np. Drove out of subdivision, everything good, great feel on pedal. Drove for about 10 more minutes, clutch pedal was solid, pushed a few times, cat started shifting great, pedal smooth. It repeated again, applied pressure, clutch went down.
Stopped at lights, in nuteral, went to hit pedal, it was solid. Pressed a few times; still solid. So I pushed hard on it, and pop, right to the floor. Car wouldn't move. Towed home to shop. Car now won't start with pedal on floor, dash message telling me to push clutch to start. Pulled slave out , pushed it in manually, but had to go to pedal to pull up by hand. Had friend push pedal and slave extended.
I am assuming the clutch hung up on input shat, thoughts? Perhaps the slave failed, master failed( considering no start) and input would help before I yank tran out.

[B7TitaniumA4]

Did you make sure to get the oring out of the master cylinder before putting the braided clutch line in? I have the exact same setup as you and as I was bleeding I was getting the intermittent stiff pedal. I pushed so hard I bend the master cylinder rod and had to replace, all over a tiny little o-ring.

I posted this awhile back when I had the issue…

https://www.audizine.com/forum/showthread.php/937969-Braided-clutch-line-install-PSA?p=14596459#post14596459

https://youtube.com/@jb_customs29
3 part video of the master cylinder replacement!

Good luck!


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[DonPistachio]

I had no idea about an o ring. I will check that asap. I wish I knew about this. As I just pulled the motor out again. When inspecting the south bend clutch no issues. I'll pull the mc out today and look for that o ring. Thank you so much for the help, I will keep u posted.

[2008s4]

I had the same issue, super stiff pedal after installing the braded clutch line. That dumb o-ring was left behind. It was tough to get out, especially when you're trying to go fast because fluid is weeping out of the master cylinder at the same time.

[DonPistachio]

Holy shit. Their was that bugger o ring. Wish I read this before..lol. I will need new master though, rod bent, car should start with new mc

[B7TitaniumA4]

That sucks dude! (Pulling the engine again)
The sellers of the clutch lines should first, create full Installation instructions and second, add this as a MAJOR tip and trick!!

As stated before, I have the exact same setup as you. After this issue and driving awhile a encountered the no start issue due to the clutch not adjusting with wear like the factory clutch does. I recommend getting the JXB extended slave now and save yourself a trip under the car later.

Also, how do we get my original PSA post to be a sticky? Enough people have encountered this issues and all over a dumb O-Ring.


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[DonPistachio]

I'm not sure about posting the post. Maybe have to be on desktop mode. You are right though, that bastard oring. And suppliers should advise all. I never want to pull this motor again. Thanks for the help. When I inspected the clutch, their was nothing wrong. I read your post shortly after, and was relieved to find the oring. Million dollar clutch did not fail! Lol

[Fallout333]

I took the plunge and bought a car from Copart. The process took 40 long minutes, but I was filled with anticipation and excitement about this new car. I arranged for it to be shipped to Ukraine and waited eagerly for its arrival. It took an agonizing two months for the car to arrive, and I couldn't wait to get my hands on it.

When the car finally arrived, it was in rough shape. The undercarriage was damaged and required repair, which took a grueling five days. The body of the car had sustained over 30% damage and took two long months to fix. But even with these setbacks, I was still hopeful and happy to have the car in my possession.

I decided to upgrade the car with an APR Stage 1, which only took a day. It was thrilling to see my car transformed into a high-performance machine.

But my excitement was short-lived. After ordering and installing an ECS SS clutch line and cylinder, I noticed that the clutch pedal was not fully depressed. It left me feeling uneasy, and I couldn't shake the feeling that something was wrong. I drove a tow truck to the station, but before I could even reach it, the clutch fell and broke the cylinder. My heart sank as I realized that my car was now broken, and I didn't know how to fix it.

I spent the next two and a half years trying to find the root of the problem. The feeling of a bad pedal haunted me every day. I felt like I had hit a dead end and that my beloved car was beyond repair. But then, after all that time, I discovered that a small ring was causing the issue. It was a moment of triumph that I'll never forget.

With renewed hope, I set out to fix my car's issues, including the elusive "Ebuchee kolechko, ya tvoy rot ebal." It's been a long, difficult journey, but I'm determined to see it through. And if I can do it, so can others. That's why I implore the forum administrators to create a prominent link on the main page to help other car owners facing similar issues. It could make all the difference in the world."

[Fallout333]

I forgot to say that I found the solution purely by accident. Because I decided to go to the forum, looking for sound solutions after removing the catalyst. And accidentally saw this post 20 minutes ago. and now, after 2.5 years, I finally know how to solve it

[B7TitaniumA4]

I forgot to say that I found the solution purely by accident. Because I decided to go to the forum, looking for sound solutions after removing the catalyst. And accidentally saw this post 20 minutes ago. and now, after 2.5 years, I finally know how to solve it

I’m glad this helped you figure out your long troubles!

The only reason I posted is due to my issue and I searched and searched and happened to find a small mention buried In a clutch line thread! I wanted to get the word out to help as it’s an easy thing to overlook since the valve end looks normal even without the Oring and the new line fits in with the retainer clip! People are bound to do experience this!


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