924Board.org

[bcblase]

OK - first major issue this morning. I went out to start Whitey this chilly morning, and the clutch pedal sprang to the floor and stayed there as soon as I touched it. I had to pry the pedal off the floor with my toe to get it back in place, and as soon as I touched it again, it sprang back to the floor.

There is no back pressure, and the clutch is not disengaging at all when the pedal goes to the floor.

What the heck happened? It was working fine on Friday before I left town for the weekend. Bad slave cylinder, pre-load spring, or worse?

Thx.
_________________
1987 Porsche 924S - track toy
1986 Mercedes 190E 2.3-16v - autocross
2007 F-150 5.4L Lariat Supercrew - tow beast
1994 Volvo 850 Race Wagon - 24 Hours of Lemons Car
2001 BMW 325xi - daily driver

[931Tony]

Most likely it is out of fluid due to a leaking... probably slave cylinder but that is just a guess. Check for leaks, replace the culprit, bleed the system and hit the road!
_________________
1981 931 For Sale... Sad to see her go.

[Smoothie]

If you find the brake fluid low and a leak on the ground under the starter area - that and the cold weather give you all the symptoms of a worn clutch slave seal. You might get a little more use out of it by refilling the reservoir and pumping the pedal. If it comes back with that, and you're feeling courageous, you may be able to drive it some more, but keep a bottle of brake fluid in the car just in case. -And either drive it to a shop or order yourself either a rebuild kit (partsamerica.com has them at about $15) or a whole new slave cyl (something like $70-$90).
If instead of leaking outside on the ground, you find a leak on the carpet behind the clutch pedal, then that would mean the clutch master cyl is leaking, and in need of either a rebuild or replacement.

If it's the slave cyl, give the starter solenoid a cleaning while it's out. Some of the fluid from leaking clutch slave cyls tends to get into the starter solenoid where it attracts moisture - that and dirt combine to gunk-up the solenoids' armature (piston), disabling the starter.
If you'll be doing the work yourself, do a search for all terms on slave starter by author smoothie. I have directions floating around here somewhere on bench bleeding and replacing the slave in a way that eliminates the tedious under-car bleeding process later.
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"..it's made in Germany. You know the Germans always make good stuff."


'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

[Rasta Monsta]

. . .and if you find brake fluid in the passenger compartment, scrub it out or you'll end up with a hole there.
_________________
Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[bcblase]

Yup - brake fluid has been running low, and there has been a bit of a drip under the car.

Starter was replaced a couple of weeks ago - I'll make sure I check the solenoid while I'm under there.

I'll check the other cylinder culprits listed above.

Thanks for the help!
B.
_________________
1987 Porsche 924S - track toy
1986 Mercedes 190E 2.3-16v - autocross
2007 F-150 5.4L Lariat Supercrew - tow beast
1994 Volvo 850 Race Wagon - 24 Hours of Lemons Car
2001 BMW 325xi - daily driver

[joecitizennn]

Always comes with cold weather. I remember when I had my first 924S, I attached an elastic cord to the pedal and ran it to the seat rail. It allowed me to drive the car untill my parts came. This kind of behavior will occour with the reservoir topped off too. You will notice it badly early on a cold morning, then, when the car warms up, things may work again for a while. The slave on my other 924S went out this way just 2 months ago.
_________________
87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold

[bcblase]

Phew!

First major surgery (for me) has been accomplished. I got the clutch slave unit and the master cylinder removed from the car - the master is a pain to get access to!

I did break the hydraulic line trying to detach it from the slave unit. The line was severely corroded at the nut that threads into the housing. The bore on the slave cylinder look OK - nice and smooth.

It looks like the hydraulic lines were reversed at some point. The line with the rubber section was threaded into the slave, and the solid line was threaded into the master. This does not jive with the parts diagram for the car, but it seemed to work, and the solid line has already been bent to fit into the master cylinder. Does this really matter?

BC
_________________
1987 Porsche 924S - track toy
1986 Mercedes 190E 2.3-16v - autocross
2007 F-150 5.4L Lariat Supercrew - tow beast
1994 Volvo 850 Race Wagon - 24 Hours of Lemons Car
2001 BMW 325xi - daily driver

[joecitizennn]

I dont think the line would have been reversed. Regardless, it does not matter as long as it doesnt leak.
_________________
87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold

[bcblase]

Got everything finished up this evening - new clutch master and slave clylinders, plus a new clutch line. The clutch line I received was short by about 3 inches, so I had to re-route the line slightly to make-up for the shortness.

Seems to work fine - the power bleeder I got worked great, and the clutch is very tight now - you barely have to press it down to get it to disengage now. Should be good for Autocross in the spring.

BC
_________________
1987 Porsche 924S - track toy
1986 Mercedes 190E 2.3-16v - autocross
2007 F-150 5.4L Lariat Supercrew - tow beast
1994 Volvo 850 Race Wagon - 24 Hours of Lemons Car
2001 BMW 325xi - daily driver