Passat (B5) :: 1999 - Clutch Pedal Would Not Come Up Off The Floor / Stuck


Sep 19, 2006

Facts: 1999 Vw passat 1.8t

1 year ago, clutch pedal would not come up off the floor, no life in the pedal.

Problem: Clutch master cylinder, replaced.

6 months ago, clutch finally went bad. Took car to clutch shop, replaced clutch kit(found out after i payed that they only turned the dual-mass flywheel... ). Get car from clutch shop, the clutch pedal came up only 2-3 inches off the floor by itself but you could lift the pedal with your hand or foot, and it would come back up all the way, but it was life-less. It was not pulling fluid in. It was catching extremely low. I called the shop, they said that it was just because it was a new clutch and it would get better. I didn't believe them.

Two days ago, I got into my car and couldn't get it into gear. Clutch pedal would go down with the same amount of force as before. Took it back to the clutch shop and explained the history with the clutch master and then them doing the clutch kit. They said it wasn't bleeding properly and they're not sure if its going to have problems again. Car is working now, but I am concerned that it will have similar problems again.

The tech who fixed it said he pumped fluid into it extremely hard, and that's what made the pedal come up all the way (no longer stops 2 inches off the floor) and its going into gear just fine now. What the problem might have been? Block in the hydraulic lines? If this is the case, does forcing fluid through it fix it?

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My clutch pedal went all the way to the floor. The engine was missing first and then that problem happened with the clutch. I had the car towed to my business, I checked it the other day and the pedal was up. The clutch still doesn't engage.

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I've been driving manual 12 years, all my driving life, and been in 10+ manual vehicles during that time, including a 10+ year stint in a 1.8T Passat with a 5-speed.

In all that time, and all those experiences, I've never replaced a clutch, damaged a clutch, or had one problem. In fact, I consider myself a very good operator of the manual transmission.

This is preface to my current situation. 2009 Tiguan (early build) 2.0T 6M, driving at 57mph in 6th gear - downshift to 4th to pass a truck and WHAM. Grinding, confusion, and then the clutch pedal stuck straight to the floor. Glide to a stop on the side of the bayou road.

Totally immobile vehicle. Impossible to shift into gear, or get the pedal off the floor except by pulling. Smell of acrid smoke.

VW dealership says "we're doing a courtesy warranty repair" on the clutch, flywheel and bearings, as if it's my fault. Impossible. This is a mechanical defect if I ever saw one.

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Last night I was driving home and decided to show off at a light. I punched it pretty hard, but it wasn't anything outrageous.. anyway, as soon as I shifted to second, my clutch pedal gave out and dropped to the floor without resistance. I coasted it to a gas station, luckily.. When I lifted my foot the pedal rose back slowly. I tried pumping the pedal, didn't work. I looked for leaks, but none were found. I turned it off, put it in first and tried starting it, and it turned over and jumped/jerked forward, a lot like it did right when I shifted into second and it went out. So I'm assuming that its not the entire clutch cause it wouldn't have engaged the engine. It's not a leak. pumping it didn't work so it's can't be a pressure issue.. what is going on? is it my master cylinder, or maybe my slave?

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In the first instance of this problem, my brake pedal was stuck to the floor. By pumping it a few times, it gradually released and rose to the proper level. Brakes then seemed to work fine for a couple of weeks, until I reversed out of a parking space, but could not brake the car when I shifted into drive. I pushed the brake pedal to the floor, but could not stop until I ran over two large boulders that, stopped the car short of a big tree.

My mechanic doesn't know exactly what went wrong, but is replacing the brake cylinder. I fervently hope that fixes the problem! What could it be?

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I'm looking for some wisdom as a few blogs/websites point towards a master cylinder, others say the master and slave, and my local auto shop said I need to replace the entire clutch assembly and throttle bearing. My truck is no spring chicken anymore but I'd like to keep it running for a few more years...

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What is failing. I have a 2000 F350 PSD with 116k miles. When I bought the truck last year, I noticed that the clutch pedal would squeak while it was coming off the floor. It doesn't happen when the engine is cold. I need to drive it about 30 min before it starts to happen. On longer trips, several hours, the squeaking is louder and the pedal gets very stiff. When I stop for fuel, I've come close to stalling when coming out of 1st gear. I can push the pedal to the floor, but on the way up, the pedal squeaks, and then once I reach a certain point, say 3-4 inches off the floor, the pedal looses all freeplay. The best way for me to describe it is the pedal travels up faster than it normally does when it's cold, and if I don't compensate with more throttle at that point, it will stall.

I've learned a lot by reading this forum for the past year, but I don't know the first thing about how to diagnose problems like this. I've taken it to 2 mechanics for test rides -- one thinks the clutch is fine and thinks the problem is the slave cylinder or a broken bushing in the pedal.

The other shop is also a small independent shop, but they specialize exclusively in Ford trucks, so I thought they would be more knowledgeable. But now I'm wondering if they could sense my ignorance and are taking advantage of the situation. They also took it for a drive, but they think the slave cylinder is fine and that the clutch needs to be replaced. I questioned him about the slave, and he pulled it to look at it, and asked me to push the pedal slowly while he was under the truck. I still had a little resistance and a faint squeak even in this situation. But he said the hydraulics are so simple that he felt we could rule that out. I can't remember exactly what he said, but I think he believes one of the springs in the clutch plate has failed. I just know they are suggesting a new clutch and they want to machine the flywheel to original specs.

I thought the leading symptom of a failing clutch was slippage under a load. So under strain, I would expect my engine to race occasionally, like I'm in neutral. But I've NEVER experienced anything remotely like this, even when driving hard in the hills pulling my travel trailer.

I know something is wrong, but based on my limited knowledge, I'm not sure what. It's getting a little harder for me to move the shifter into 1st and reverse, but once it's there it's fine. I've never experienced any racing or slippage in any gear. The one definite symptom I have is that squeaky pedal that when driven for a couple of hours, gets so stiff that it can cause near stall outs. With those symptoms, what do you think is going wrong?

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MAH00111 - YouTube

MAH00115 - YouTube

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My guess is I need a new clutch master cylinder. I have plenty of fluid in there although its a bit old so I'll be changing that when I change the cylinder. Could it be the slave cylinder? If so is it a bear to change that? (do I need to drop the trans?)

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Cars setup is around 375ish whp. I know I could spend 1300 bucks and call it a day for a clutch master or south bend but was seeing if there is a cheaper alternative.

Also If I were to buy an OEM clutch or an upgraded one that was not rated for up to 400~whp would it drive and pull the same as a fully upgraded one just not last as long?

6 Speed ...

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So cold out I'm not sure I want to tackle this right now, what to look for and where?

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