Clutch Pedal Sticking

[JVD]

Ok... I'm about to give up on this thing and send it to a shop. Here's where I'm at right now.

Brand new FX400 and TTV flywheel.

Brand new slave and master. Both have now been replaced twice.

Brand new USP slave line.

Clutch has been bled a million times. You can drive the car and it holds 400ft-lbs but if you push the clutch more than like an inch the pedal will stick to the floor. It's like there's not enough pressure to push the pedal back up. If I remove the clutch pedal spring the pedal returns on it's own. With the spring in it requires quite a bit of force to pull the pedal off the floor.

The only thing I can think of now is that I put the clutch spring back in wrong or something in the bell housing is messed up. Can someone please throw some ideas out to me? Something I may be missing?

Does anyone have a pic of the spring orientation? To me, it seems like it can only really go one way... but maybe I'm wrong. Is the spring there to return the clutch back up or to make it easier to depress the clutch?

[JVD]

Also forgot to mention that the engagement point is like 3/4" from the top of the throw. Suuuuper high.

[Monty23]

Sounds like the PP may be going over center. You may need to install a clutch stop.

[christianb5s4]

I have a similar thing except it doesn't stick to the floor, it's just soft after shifting at higher RPMs. Same clutch, but with Clutchmasters steel single mass flywheel, stock line, new OEM slave.

As for the engagement being high up, that's completely normal for this clutch. If you're curious about more info from other B5 S4 guys running that setup, check this thread out:

http://www.audizine.com/forum/showth...s-FX400-owners

[JVD]

Hmm... so how can I remedy this if that is the issue? Is the slave overextending the diaphragm? Can I get a shorter slave rod or shorten the one in it? I should also mention it has a metal slave from Rock Auto in it now with whatever rod that came in it.

As it sits now, I'd have to put like a 2" stop behind my pedal for it to be usable. Lol.

I'm honestly tempted to abandon this clutch setup but don't feel like pulling the motor again. TTV B7 flywheel + cheapo Luk setup is tempting.

[julex]

You're overextending diaphragm I think. You will have high clutch with almost any set up that holds any appreciable TQ.

Rod length has nothing to do with it since rod always pushes at fork and the amount of it extending when you press pedal is a pure function of slave rod diameter and amount of fluid pumped by slave master during pedal travel. If you start screwing around with rod length, all you will accomplish is that you might end up with a rod that will be too short and will cause slave cylinder to "pop" sometime down the road once clutch wears in.

Anyway, see here: http://www.audizine.com/forum/showth...=1#post8405810

Install pedal stop, you'll have to fabricate something. Adjust it so that it goes about 1" max below first engagement point. This way you will also have far more predicable engagement point as well.