16V Clutch Problem (again)

[scos]

Got a problem with the clutch on my 16V - again.
Put a new one in a while ago and had a problem with the pushrod not aligning with the lever that is operated by the cable. I managed to realign it just by pushing the rod back into place but then today it did it again. Weird, it drives fine for weeks and then randomly the pushrod 'jumps' out of line with the lever. I can see that it is only held in place by the shape of the 'domed' head fitting in the curved recess in the lever but it should stay I guess? Unless the lever overshoots on the return? That's only thing I can think of that might cause it. Should the mechanism be held in compression somehow? Maybe the clutch cable is allowing it to return too far after depressing the pedal?

Anyone else had this problem? At the moment I'm thinking about modifying the mechanism somehow but there must be something wrong if it's doing this

 

[scos]

Had a look at the mechanism today and I think I have an idea what the problem might be.

It appears the only thing that stops the pushrod from becoming misaligned with the lever is the fact that it's under compression. When the clutch is operated the compression is provided by the cable (obviously). But when the pedal is idle the compression is provided by a small spring that fits over the pushrod. I popped the rod out just now and the spring is damaged at one end so probably only gives about 60-80% of it's normal force. I'm gonna try replacing that and see if it cures the problem.

As usual I'll keep you posted peeps....

 

[scos]

Right, an update.....

Called VW and Seat trying to order a new spring and lock washer but no joy yet. They both said "oh, that'll have to be a special order part.....erm....." - Well f***** order it then you muppet! Neither of them got back to me with the details (as is usually the case with VW/Seat supoport). In fact why is VW/Seat customer service so poor??! In fact I'm gonna start a new thread on that very subject....

I think it's going to be easier for me to try and get the spring myself. I've found a very similar one at work that's abit longer so for the moment I'm gonna cut it to the right length and try that instead. Then I'll try and order the right one from RS or something......

 

[scos]

Got a similar spring from work (it's an engineering company) and chucked that in. The spring is a little stiffer which has made the clutch even heavier than it normally is but so far so good.

So I guess that was the problem then. Hope that helps anyone if the have thye same problem in future.....

 

[crezz]

would the stiffer spring put more pressure on the on the pedal? arnt they prone to cracking?