This clutch setup is the devil

[DarkoNova]

So it's been like 3 weeks since I killed my car by trying to bleed the clutch. I couldn't get fluid out of the slave no matter what I did. So after determining that I wasn't getting flow out of the master cylinder, I pulled it out and bench tested it. Nothing happened when I pumped it.

Ordered a new clutch master cylinder. Fluid came out when i bench tested it. Hell yeah, thought I'd be back on the road once I got it installed. Installed it, filled the reservoir and called it a day (I work swing shift/graveyard so I try to work on it after work at 2am). Went to bleed it the next day and the reservoir was empty. Firewall was wet, inside and out.

Saw the line that goes from the clutch master to the clutch slave was kinda gouged at the sealing barb, so I ordered a new one. Pulled the brake booster to get room, pulled the old line, installed the new line, put booster back in, filled reservoir, called it a night.

Went to bleed it and had an empty reservoir AGAIN and brake fluid on the inside and outside of the firewall. Pulled booster out to get room to access the line coming out of the master. Pulled the master and connected it to the line on the engine side of the firewall (so instead of the clutch master being inside the car, it's under the hood). Filled the little hose on the master with fluid and let it sit for a bit.

There's little holes where it looks like the Teflon seal inside the master just clips in, and the brake fluid is coming out of there. Which explains why it was on the inside of the car, since those holes are inside the car.

Is this a bad clutch master? I mean it came with a new retaining clip, and it doesn't seem like I can pull the line out with the clip in. I can push it in a little bit, though. Not much, but still.

I'm at my wit's end with this car. I just wanted to get a firmer clutch pedal and it's been something like 3 weeks since I've even driven the damn thing. I've wasted a ton of brake fluid.

I don't want to throw in the towel, though.

Help, please.

[texasboy21]

These clutches are hard to bleed. Were you using a power bleeder? It takes a bit more pressure compared to the brake calipers.

[Nollywood]

I've never had any issues bleeding a B5 or B6 clutch, even after installing new master and slave cylinders, which means dry components.

[Charles.waite]

Well I do know one thing, I'm pretty sure that brake fluid isn't supposed to leak out of a master cylinder like that...

I would call the place you bought it from and exchange it. Sounds defective.

[DarkoNova]

Sorry it took so long, I was dead tired. Anyway, here's a couple pics of what I'm talking about (sorry, they're huge, lol):




That little square, there's one on each side, and fluid is slowly leaking out of it. Even with no pressure, just filling the reservoir and letting it sit, the entire reservoir will drain through those holes.

Maybe I just need a new retaining clip, but I still don't think it should be leaking there. If the clips were weak, I'd imagine it would leak between the line and the master...

[Nollywood]

Looks like the seal on the end of your hard line, is sealing above the mating face. Either there's a gouge in the sealing surface, in the seal, or the seal has moved up on the hard line.

The clip won't be the issue here.

[DarkoNova]

A gouge in the seal of the master?

It can't be a gouge in the hardline, I had this issue with the old hardline which is why I ordered a new one. New one is smooth as a baby's butt, lol. I still have the issue. It's a Sachs part, it even has the 4 rings but they were ground down.

I already set up a return and ordered a new master. Now more waiting. -_-

[Charles.waite]

So, question here, what year is your car? There was a VIN split in 2004 when they switched to a different Slave Cylinder. The one pictured is the later style, that was used on the late 2004, 2005 and all B7s. My 2004 was an early one and had the early style Slave cylinder. It could be you have the wrong style?

Regardless, I'm pretty sure those holes aren't supposed to be there. They don't appear to be on the OEM ones judging by the pictures on ECS...https://www.ecstuning.com/Audi-B6_A4...tch/Hydraulic/

[DarkoNova]

My car is an 04 as well. The slave isn't the problem, it's the master. The hardline I ordered matched my stock one perfectly, and the clutch master did, too. Just, apparently the master is defective.

That's what all signs are pointing to, at least.

And now it's gonna be a week before it gets here. So yay.

[old guy]

I don't know if this helps but here is what an OEM looks like:

[Charles.waite]

I don't know if this helps but here is what an OEM looks like:

Is that the master cylinder or the Slave?

[DarkoNova]

That's the master cylinder. It looks like his sleeve is pushed further in than mine, but I'm not sure. The weird thing is the new one I bought is the same brand as OEM. Maybe I just got one of Sachs's bad ones.

I'll find out in a week if the next Sachs one fixes everything.

[Charles.waite]

Oh I was thinking it was the slave this whole time in your pictures. Derp.

[DarkoNova]

FINALLY.

I ordered the same Sachs clutch master and it showed up yesterday. So after work I went to test it and when I opened the box I was immediately thinking "wtf is this?"

I got a non-Sachs part, but it doesn't have the little holes on the sides like the Sachs one did, so I was hoping it would work.





And it freaking did.

I don't know what brand it is because I was just trying to get everything installed at 2am, so I really didn't care to check.

Got everything back together and pumped up the bleeder to a whopping 5 psi and let the fluid drain for a couple minutes. Got under, tightened the bleeder on the slave cylinder and now the clutch is perfect all the time.

I had the car running, clutch pedal held down and was just rowing through the gears all crazy because it was nice to finally be able to put it in gear again, lol.

The brakes don't feel as firm as I remember, but it's been a month since I've driven the car, so I don't really remember the firmness. Not a lot of bubbles came out of the rear brakes, so I may try bleeding them again.

Anyway, it works, so yay. Life is good again, heh.