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Clutch problem

 
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  #1 (permalink)  
Old 22 Jun 2018, 04:18 pm
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Default Clutch problem

I have fixed several things on our PT with the help of this forum, can't believe I've never posted!

Original owners Base model 2007 manual transmission 73k miles.

Car got hit and run parked in front of my house a couple of weeks ago, damage was not too too bad. Broke reverse light scratched up bumper knocked muffler into rear spring which got knocked off axle. Scraped up tires against curb. Otherwise seems good. We had just dropped insurance coverage down to liability but in TN that also covers uninsured motorists and hit & run. Lucky there. So we got a little money to fix it and I'm hoping to do most of it myself.
I got the muffler off and the spring back in place yesterday. Have new springs & insulators, shocks, and muffler on the way. Hopefully that'll do it for the rear.

My main ongoing issue in the car is the clutch. Have done the pedal adjustment twice but I think I need to go further.
It's really hard to get into gear when hot/ feels like I need more clutch rod...some time I have to pump pedal to get it in gear. Fluid level looks fine but dirty. I guess my question to you all is what would be your next step? Can I bleed the hydraulic system/ replace fluid. I really feel like it's a heat/ hydraulic issue not the clutch per se.

thanks in advance!
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Old 23 Jun 2018, 01:03 pm
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Cool Re: Clutch problem

Have you checked to see if the shifter bushings are still intact? The large bushing on the transmission likes to break and fall out... It's under the air box assembly.
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Old 23 Jun 2018, 02:35 pm
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Default Re: Clutch problem

Quote:
Originally Posted by rcktpwrd View Post
Have you checked to see if the shifter bushings are still intact? The large bushing on the transmission likes to break and fall out... It's under the air box assembly.
Thanks, but yeah I've done this with the Dorman part at least twice over the years. Finally, have some red boogers on the way! Heh, may even try to get at the one under center console.

I am 95% sure this is a hydraulic issue either at the master or slave cylinder. I have been scouring the forum pretty good and one thing I read that sounded easy enough to try was rigging the clutch pedal depressed with cap off fluid reservoir for a while. Thinking about doing this a few times and replacing the fluid somehow.

I am current in search of the service manual for download for 2007.
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Old 23 Jun 2018, 04:12 pm
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Default Re: Clutch problem

If you have never done the two under the console rhat could be part of the problem. I just did all of mine with red Booger bushing. It made a hugh difference and mine looked like they were brand new. Good luck.
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Old 23 Jun 2018, 04:58 pm
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Default Re: Clutch problem

There are two weak points in the GT manual transmission design. First are the bushings on the transmission linkage ends and inside the shifter linkage ends. Solutions here are to replace all four with solid Urethane bushings.

The second weak point in the system is the plastic linkage that connects the clutch pedal pin to the slave cylinder pushrod. The solution is to replace this part with a machined aluminum block with an integrated brass bushing.
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Last edited by _PTGT03; 23 Jun 2018 at 05:00 pm.
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Old 24 Jun 2018, 12:19 am
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Default Re: Clutch problem

Use DOT 3 brake fluid. DON'T let the reservoir go dry. Pull off the cap on the slave cylinder. Pull back one of the 2 clips. The one closest to the bleeder. Put a clear plastic hose over the bleeder and into a container. Pull the tubing back to the other clip and wait for the fluid to be free of bubbles and clean. Push tubing back in and push clip in. Top off fluid. "activate clutch pedal 60 - 100 times from the drivers seat" ?

From 2006 PT manual
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Old 24 Jun 2018, 09:08 am
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Default Re: Clutch problem

Quote:
Originally Posted by pt06 View Post
Use DOT 3 brake fluid. DON'T let the reservoir go dry. Pull off the cap on the slave cylinder. Pull back one of the 2 clips. The one closest to the bleeder. Put a clear plastic hose over the bleeder and into a container. Pull the tubing back to the other clip and wait for the fluid to be free of bubbles and clean. Push tubing back in and push clip in. Top off fluid. "activate clutch pedal 60 - 100 times from the drivers seat" ?

From 2006 PT manual
Thanks, I was glad to see that bleeder on the slave down there, gonna try this first.
One question I have is should I replace the brake fluid before I try to bleed the clutch? I am confused since they share the same reservoir/fluid.

If bleeding doesn't work, I think I may go ahead and replace master and slave cylinder.

Also excited to get the boogers in and then if all goes well maybe the rage-tek clutch pivot arm upgrade!

thanks for advice and help
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Old 28 Jun 2018, 04:28 pm
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Default Re: Clutch problem

I bled the clutch a couple of times at slave but no dice . Got the boogers in engine bay (not sure if they are seated well enough though, might check that again) have started to take center console out but can't find instructions on removal of the cig lighter or power port in front of shifter. Any help there greatly appreciated!!

I have new clutch master and slave and am going to get them in this weekend.
I bought some heat shield tape too and wondering what to wrap...the hydraulic tube? Anyone make an after market replacement that's better at dealing with heat?

I did get new muffler on. Anyone have any tips for tweaking the hangers with no welding equipment?

thanks
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Old 04 Jul 2018, 11:30 am
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Default Re: Clutch problem

**UPDATE**
Got all boogers in and seated.

I have clutch master cylinder unbolted and loose. Not sure if I can remove whole hydraulic supply tube from engine bay like service manual seems to suggest... maybe not necessary? I am currently scouring the shop for a 1/8" pin punch to disconnect the tube.



Edit ***update***

Got the pin out and tube disconnected without removal of tube from engine bay, thankfully.

On the install:
Do I just stick the pushrod in the master cylinder (it came in 2 pieces) any tips? How about how do ya remove clutch pedal retainer bushing? New master cylinder came with new one I figure I should use it before springing for rage-tek clutch pivot arm upgrade.

**Latest Update**

Got the pushrod in the master... yeah just push it in... pedal retainer bushing came off easy enough when I pulled on it hard.

So new slave and new master in and everything is put back together. I didn't really know what to wrap with heat shield tape so I'll do that some other time. I feel like it's not bled all the way though. Not wanting to go into gear. I put my phone down and took a little video of the slave moving when I depress clutch...but I guess not enough yet. Gonna try to bleed it more tomorrow, hopefully I don't have take master cylinder out and bleed it anymore... sort of a B to get in and out! Gotta hold it vertically with push rod down to bleed air out of master (I did this as installing but maybe not enough?)

wish me luck!

thanks
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Last edited by PabloCruiser; 04 Jul 2018 at 06:29 pm.
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  #10 (permalink)  
Old 14 Jul 2018, 09:01 am
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Default Re: Clutch problem

*Update*
I did some more bleeding at the slave (disconnecting it and actuating the slave rod about 50X with reservoir cap off) and it felt good until it got hot then hard to get into gear again.
Gonna try the master bleeding method of holding it with rod down for 10 secs. Sounds easy enough huh?
ugh
wish me luck
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