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Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

TD5 Clutch too high.

Hi all.

Have done a search - sorry if i've missed something that answers this.

Vehicle: 2006 TD5 90.

It developed a leak from the clutch master cylinder. Absolutely nothing wrong apart from that, clutch itself fine, bite point fine, pedal height all fine.

We changed the master cylinder for a brand new OEM part from a dealership. But we now have a very very high bite point, and the pedal is almost above the brake pedal.

There's no adjustment in the clutch master cylinder shaft that will take up this height error, (well, not enough to resolve this anyway).

Any ideas what's gone wrong? It should be the correct part as it looks like the old one including shaft length. And should at the very worst be at least as good as the pedal travel and feel that it was before we changed it. But it's far too high.

I'm wondering if it somehow has too much fluid in it, but i don't know how to resolve this..... the reservoir is the correct height and it's bled properly.

Thanks for any thoughts.

Matt.

edit: if anyone has any photos of their vehicle with it's cover off of the clutch master cylinder housing would be greatfully received, google image search never answers the question of "was it actually OK when this was taken or was it causing issues"!!!

7th Mar 2016 1:32pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Click image to enlarge

Click image to enlarge

hight adjustment you use two nuts as shown pic one ( 2 )

Click image to enlarge

Click image to enlarge

pic from my 06 td5 90

Last edited by dorsetsmith on 7th Mar 2016 3:18pm. Edited 1 time in total

7th Mar 2016 2:14pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

Thanks for the photos, sadly on ours there's not sufficient thread available to get the pedal height to meet that spec. So am stuck. It is adjusted as far as the nuts will permit without running off the end of the shaft. The lock nut is barely in contact with the nylon part of the locking feature and the shaft. Therefore I'm thinking the shaft should be settling further in by default.

7th Mar 2016 2:24pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

which end of the thread are you working with ( cylinder end )

7th Mar 2016 2:29pm

Fatboy Slim

Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

If your pedals too high you want to adjust it the other way from the sounds of things if the locknut is nearly off the end of the thread

7th Mar 2016 2:29pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

I'm not even sure there's enough thread there to get all the nuts on and still have any adjustability anyway to be honest.

Tell you what I'll take some photos later and post them up.

Thanks for the helps guys really appreciate it. Will see if someone can take a pic for me. Not with it at the minute.

Will show you the problem.

7th Mar 2016 2:33pm

Fatboy Slim

Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Good man. You might end up putting a shim in between the slave cylinder and the bellhousing. Stick some pics up and we'll have a look

7th Mar 2016 2:37pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

Ok here goes then.

A photo or two. All fairly self explanatory.

Anyone see anything unusual or strange?

The clutch is way too high.....

Click image to enlarge

8th Mar 2016 10:06pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

the cylinder push rod look ok looks no different my one up the page

if you slacken the two nut and re adjust it slightly you will get the pedal hight down slightly

Last edited by dorsetsmith on 8th Mar 2016 10:22pm. Edited 1 time in total

8th Mar 2016 10:14pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

That's what I was thinking.

See what I mean about the adjustment? No way there's enough adjustment left to get the pedal down to where it should be.... Unless I'm missing something.

8th Mar 2016 10:15pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

you can adjust it and it will be ok if you look at my one up the page i have no thread showing and the pedal is find. if you change enough master cylinders you get to right every time

Last edited by dorsetsmith on 8th Mar 2016 10:30pm. Edited 1 time in total

8th Mar 2016 10:24pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 688

I'll have a go and see what it gets me to. Worth a try I guess.

Will take a shot when it's done and see!

I guess the lever ratio is significant so even 3 to 4mm which is all I reckon I've got might have a big effect at the other end of the pedal.

8th Mar 2016 10:30pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

that right

8th Mar 2016 10:31pm

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