Clutch arm problem

[Gazz]

Hi folks,
First post so first things first. Excellent forum with a heck of a lot of terrific content so well done to all concerned and I look forward to putting in my tuppence worth where possible.

My problem is a head scratcher in that I have a 2002 406 2.0 hdi (110) estate, had it for 5 years and never a bit of trouble with it, however, one day foot goes direct to floor on the clutch. AAAHHHH!!!
Ended up replacing clutch plate, bearing, and dual mass (decided to do the lot as advised). Now the problem.

The clutch fork release arm seems to be pushed right over to the left (on looking from the front of car), no matter what we do it is not sitting properly.
Has anyone any idea as to what may have gone wrong? We (a friend and I) have had the gearbox in and out 3 times now but can't get our heads around the problem.

Any help would be appreciated.

[jasper5]

The clutch is a "pull" type clutch where the release bearing is clipped into the pressure plate via a circular spring clip....what you do is to lightly grease the spring clip around the bearing and the opening in the pressure plate....you then have to pull the release arm from left to right until the spring clip clicks into the pressure plate...it might take a good bit of force to do it....use a lever between the release arm and the gearbox case.

When you manage to get the bearing engaged into the pressure plate and finish off the job the clutch biting point will be very close to the floor until the clutch beds in a bit.

Make sure that the release bearing has not clicked into the pressure plate before the gearbox has fitted fully home to the engine....if this has happened you will need a new clutch.

[Gazz]

Brilliant explanation Jasper. Thank you very very much. I was at the head shaking, "where;s my blowtorch" point.

[Gazz]

Ok turns out this has all been tried. But the clutch is almost all the way out. Does the clutch release fork bend easily? I have read about folk having to replace them and wondered if this is an issue and if so how can you tell if it's slightly bend.

Sounds stupid but it's the only thing I can think of having replaced everything else.

[jasper5]

When the gearbox has been pulled out again has the release bearing stayed connected to the pressure plate?

[Gazz]

Hi jasper. Yep both times.

[jasper5]

Hi jasper. Yep both times.

So, did you take the bearing out of the pressure plate then start again? Clicking the bearing into the pressure plate each time?

What exactly is the issue? Is the clutch pedal solid and won't press down?
Does the lever arm feel very slack or does it feel like there is just a little bit of play in it?

[Gazz]

The pedal only has half travel as the arm is almost right out.

(Halfway between floor and normal position). The system was fully bled so can't work out what the problem can be except possibly a bent fork?

ps. Yes reattached the bearing each time

[jasper5]

Very strange
It is possible for the lever top bend, but couldn't tell you how to check it apart from putting it next to another (good) one.
One thing to note is that the slave cylinder on these (push in and twist type) is easily damaged, especially if you use force on the slave cylinder body...ie, using grips of some sort to screw it in.

Short of looking at the problem, I can't think of anything else.

[Gazz]

HI Jasper.
Finally worked it out. Turns out there are 2 clutch kits for the dual mass system and, one of which has a large lip. We were supplied with this one from the motor factors as it's the only one they stock. Having measured ever bit of the kit against the old one we finally managed to pinpoint the problem. A wee visit to the peugeot dealers and new one purchased and now installed. Everything is now right in my little world yet again.

Thank you very much for all your input as it is always appreciated when someone is willing to help a total stranger. Hopefully I'll get the chance to repay your kindness.

[jasper5]

HI Jasper.
Finally worked it out. Turns out there are 2 clutch kits for the dual mass system and, one of which has a large lip. We were supplied with this one from the motor factors as it's the only one they stock. Having measured ever bit of the kit against the old one we finally managed to pinpoint the problem. A wee visit to the peugeot dealers and new one purchased and now installed. Everything is now right in my little world yet again.

Thank you very much for all your input as it is always appreciated when someone is willing to help a total stranger. Hopefully I'll get the chance to repay your kindness.

That's brilliant
I couldn't think of anything but the clutch being the problem.
It's useful to take note of the solution to a problem like this in case it turns up again

You are very welcome
I have 45 years experience repairing motor vehicles, so if I can help someone then I will try my best