[Stendec]

Returning home at the end of a 200 mile trip on Sunday with no problems. Approaching a local roundabout a few miles from home the clutch failed. Managed to complete the journey home by "starter motor pullaways" and clutchless changes.
The clutch hydrolics appear ok, about 10mm movement of the actuator bar out from the slave cylinder. I assume this is about what it should be? The arm to the gearbox/clutch assembly is not loose or floppy.
This car had a new clutch fitted about 18 months ago and has shown no signs of wear since.
Anyone have any ideas what could have caused this sudden failure?
Any help or advice appreciated,
Stendec.

[David W]

Hi, get someone to operate the clutch pedal & see if the clutch fork to the bell housing moves in & out freely. If not its the clutch cable. The most likely problem. Otherwise the centre plate is burnt out but so so unlikely. You would have smelt a "horrible" burning smell, (a bit like burnt cabbage!) Good luck, David

[Stendec]

Hi David, thanks for your reply. It failed coming up to a roundabout on the A30 after about 70 miles of open dual carriageway in 5th gear so no heat built up or burning smell. It's a hydrolic clutch and the hydrolics seem ok. About 10mm movement at the actuator bar out from the slave cylinder. The arm from the slave cylinder to the gearbox/clutch bell housing is not loose or floppy and seems to move normally. That only leaves the thrust bearing area but I can't think how that would just break. Just wondered if anyone else has had a similar experience.
Thanks,
Stendec

[Stendec]

P.S. Can anyone tell me what the movement of the clutch actuator slide bar out from the slave cylinder should be? This one is about 10mm.
Stendec

[E_T_V]

The movement doesn't sound too far wrong to me.

Does the clutch pedal feel normal, i.e. is there the right amount of spring in the pedal still?

If so then chances are the friction plate has broken up causing the clutch to jam up.

If not and the clutch arm is floppy then check there is fluid in the reservoir if you haven't already, and look for any fluid leaks.

[Stendec]

Hi E_T_V, thanks,
The clutch pedal feels normal pressure, movement etc.
The arm between the slave cylinder and the bell housing is normal, not floppy.
Everything looks and feels absolutely normal, except the clutch just refuses to release.
No rattles or noises from bell housing suggesting break up.
Next step, open up clutch assy/bell housing?
Stendec

[Stendec]

Despite the weather (working with the car on ramps in my drive) I have finally got to the reason for the clutch failure. A piece of the friction plate has broken off where it is flanged out to hold one of the springs. This has resulted in the spring coming loose and jamming between the pressure plate and the friction plate, preventing any movement of the clutch to release.
This clutch was only replaced in January 2008 so has had less than two years use. Despite the fact that this is obviously a faulty clutch plate, when I took it back to our local (Redruth) branch of S.E.S. Autoparts they were not interested and said it was only guaranteed for a year so were not prepared to provide a replacement or a refund.
Another new clutch kit, about £100.