s4 clutch pedal travel

[triumphelan]

My pedal opperates nearly on the floor ,I have had a new clutch about 6k miles ago and it has always been the same .Is there any way that I can adjust the actuation position of the pedal?do I have a problem with the masteror slave hydraulic cylinders?
regards John

[freddy22112211]

John,
If it's working OK that's the best position - it's quite uncomfortable with it higher. Of course it's not good if it's too low - ie need to pump the pedal. You can adjust the clearance at the master cylinder to nearly zero to make it somewhat better, but otherwise you may have a problem somewhere (but unlikely if it's always been like it).
On LHD cars the flexible clutch hydraulic tube can be old and soft and cause this problem.
There's quite a lot of posts on using different sized cylinders for one reason or another in the archives.
Gordon

[StressCraxx]

Check the clutch fluid level.

The red plastic hose is a possible problem as discussed above. On LHD cars they tend to melt from the exhaust heat, or just get old and crack and start to leak. Some of of us Yanks have installed braided stainless clutch lines to solve this. The stainless line can act like a hacksaw if allowed to rub on anything, so cover it with a piece of split rubber hose where it rests on or near anything. Its not a bad idea to do this for the plastic line to keep it from wearing through on the chassis.

Also check to make sure the master or the slave is not leaking fluid. If the master leaks, there will likely be fluid on the carpet in the footwell.

It is also possible the slave itself is loose in the fit of the bell housing bracket. The slave is held on the bellhousing with a circlip. After many thousands of miles, the fit loosens up from wear. Adding a second circlip to hold it in place takes away almost all of the slop.

It could need adjustment on the pushrod at the slave if the pushrod locknut has come loose. Instruction on how to do this is clearly illustrated in the shop manual.

Happy Lotusing!

Dan Wise
Elan Dhc/S3-Super Safety
45/7279

[gjz30075]

Make sure the system is bled really well and the pushrod properly adjusted. Having determined that, have someone in the car to slowly push the pedal down and it should move in sync with the pushrod out of the slave, after the play in the pedal is taken up. You could also have a cracked fork.

Greg Z
'72 Sprint

[triumphelan]

When I pump the clutch pedal I get some abnormal results ,the operating point moves to differant places thro the pedal travel .When I bleed the clutch "er indoors" did the pumping ,not a good idea she was more conserned about the neighbours new curtains that the pumping which made her leg hurt .I shall get a competant person ,a man and do it again .wiil post results

[GrUmPyBoDgEr]

Hi John,
I quote your original posting:-

"My pedal opperates nearly on the floor ,I have had a new clutch about 6k miles ago and it has always been the same".

Was it like this prior to fitting the new clutch? ("and it has always been the same")
If not, the depth / length of the new clutch, could it be shorter than the original & thus require more pedal movement until the thrust release bearing comes into contact with the clutch. If so only a high degree of adjustment will compensate and it could be that a longer thrust release bearing carrier would be necessary.
Appologies if I've missed something somewhere along the line.
John

[gjz30075]

John, it sounds as if the slave cylinder is floating a bit too much. There is a small amount of back and forth action on the slave and I eliminated all the motion on mine by wrapping the slave with a 14g copper wire opposite of the circlip. My slave cylinder is now stays in one spot and the engagement point doesn't change.

Greg Z
'72 Sprint

[triumphelan]

I think I have an hydraulic problem ,master /slave cylinder.
I get judder at low speed takeoff [see earlier posts].I renewed the clutch about 6K miles age ,just to cure this problem which it diddent .I don`t know the age of the master/slave clutch cylinders although there is no apparent fluid loss.
I shall probally change them both.
I`m waiting for a ramp to clear in a friends garage to investigate more.

[purplepete]

Do you totally trust the guy who put the clutch in for you?-Could it be that packing clips are still under the fingers?
just a thought!

[triumphelan]

Good point ,I put the clutch in ?????
Always blame the fitter, thats what they did when I was working

[Dag-Henning]

There are also two different types of clutches you can fit ; with or without centerpad, and release-bearings to go with them ( - flat or round) If you mix them up, you can get into what you describe.

Dag

[triumphelan]

My local parts supplier needs to know the number cast onto the slave cylinder,I have given him the girling number 64067950, from Garaths list of everthing fitted to Lotus and where they were soursed from[what a great list this is ,it has save me lots of time and money ]
Has anyone got a slave cylinder handy and can give me the number cast on it

[prloz]

Hi John,
I have a spare clutch slave cylinder.
Number appears to be 64673347.
Regards,
Peter.

[triumphelan]

I have bleed the brakes and there is no noticeable differance in pedal operation .I shall replace the two cylinders one at a time starting with the master

[triumphelan]

Could someone check their clutch pedal movement and tell me if there is any change in feel /clutch operation or position the clutch engages when they give the pedal a second /third pump