Tiguan :: Grinding When Downshift / Clutch Pedal Stuck Straight To The Floor


Sep 8, 2010

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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Any clue as to what could caused this overnight?

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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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I can't remember if the brake light came on last time. This time it did. Both times the fluid in the reservoir was full and looked to be relatively clean. Both times there were no apparent leaks in any of the fuel lines, abs module, at the cylinder, etc. I'm no slouch when it comes to car repair. The master cylinder replacement was done correctly, the lines were bled properly.

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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?

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