1997 vw polo clutch problems

crzybkr73

Hello. i have just done a complete clutch replacement on my 1997 1.6L petrol polo. it was good for 2 days but now the pedal has dropped half way down and is extremely difficult to get into gear (grids in). the clutch cable was replaced about 6 weeks ago. i did notice that on the old thrust/release plate the little stud in the centre was broken off.i do not know many technical terms so i apologise now. pedal box seems ok also. would this little stud being broken have worn the long bar that comes from the selector side of the gearbox enough to cause this problem. if anyone has any ideas just throw them at me please as i need this car badly to get to work.
Thanks in advance for any help, it is all very much appreciated

Mech1

Does your gearbox have the clutch actuating rod that goes right through the gearbox?

Mech1

If it has the rod, then check the pawl item no 20 for cracks / slippage on splines.

crzybkr73

i am not sure what you mean. it has a self adjusting cable. what i am calling the thrust bearing is a solid domed disc with i riveted disc in the centre. i presume that the rod you mention pushes on this. i would need to remove the clutch again to check this

crzybkr73

sorry did not see attachment

crzybkr73

i believe part no 24 is the rod i am referring to, and no 14 is the thrust bearing as i call it,
would you have the list of names for the parts available also, so i can call things by their proper names?

Mech1

ok so this is the type of clutch assy that you have.
I dont have the listing for the diagram to hand, but part no 20 has been known to fracture causing similar symptoms as you discribe.
My first check would be pedal box but you say its ok, the cable self adjuster could be faulty but you say its new so next is the pawl part no 20.

This can be removed without removing the gearbox, about 30min job to replace.

crzybkr73

great news, just spoke with a breakers yard and they say that the rod can sometimes penetrate the bearing (which i think is part no 16 or 23)also. sounds like a strip down job then, but i shall try your solution first as it seems the easiest. thanks a million for your efforts

Mech1

the bearing is item no 16, you fitted a new thrust plate no 14.

bearing and pawl can be removed with box in situ but you will need a new end cover no 13 as you will prob wreak it removing it. also be ready for a little oil to come out.

crzybkr73

thanks again

johnayo

+1 on the pedal box. Well known problem with these. And gives these exact symptoms.

crzybkr73

yeah i thought it was the pedal box before but replaced cable(when i finally tracked down the correct one) and solved the problem(wrong cable was installed before, thus causing severe clutch wear). then this problem occurred. i used to own a diesel seat Ibiza 1998 so had some previous experience with the gearbox and pedal box

johnayo

crzybkr73 wrote: »

yeah i thought it was the pedal box before but replaced cable(when i finally tracked down the correct one) and solved the problem(wrong cable was installed before, thus causing severe clutch wear). then this problem occurred. i used to own a diesel seat Ibiza 1998 so had some previous experience with the gearbox and pedal box

Well done. at least your sorted.

crzybkr73

got the gearbox sorted by replacing the part no 24 & 16. it went well up until today. suddenly lost all clutch and could not change gears. i think the small rivet may have broken off from part no 14.
my problem with this is that this is a new clutch(couple of months old now) and i dont see how this could break so soon