Back with my clutch issues, sigh

[my_citi1.8i]

Hi All,

So i had my 3rd clutch replacement done in less than a year and still facing the same challenges. The clutch dont want to fully disengage when i get to a halt and the car is in a gear. Smooth gear changes when the car is switched off. I can drive for about 30 minutes in traffic then i struggle to get 1st and 2nd gear. This is a citi1.8i, 2007 model. 'All parts' has been replaced. The car basically moves forward when halted. If i pull up the handbrake then it does the dip due to the force. At this point the gear is stuck and i need to force it out. What could be the reason?

Thank you in advance.

[Killerwatt]

Is the cable correctly adjusted?

[my_citi1.8i]

Is the cable correctly adjusted?

As far as i know yes. Its a brand new clutch cable from Goldwagen. Current clutch kit is LUK. New pushrod, release bearing, seals etc

[my_citi1.8i]

Comment from a WA Group:

The flywheel step to surface height must be exactly 23.6mm. If it's less. The clutch will disengage prematurely. Problem is when most shops skim they only skim the surface. And ignore the step. In many cases you get away with it. But in your case you didnt. Then your mechanic probably saw the flywheel was skimmed recently and just replaced the clutch. That's why you having the same problems all the time with different clutches. Because the flywheel wasn't mic'd up and reset. You need to send the kit and flywheel to a specialist. Hel measure and set the tolerance correctly. Trust me. I had that same issue many times before

[panic-mechanic]

Yeah not enough info to comment. You had the clutch changed 3 times? Was this to solve the dragging issue or something else, was the flywheel skimmed at any point, have you tried a new flywheel. Have they looked at the finger in the box that pushes the pin that pushes the pressure plate disc? You say everything was replaced. Please specify what everything entails?

[my_citi1.8i]

Yeah not enough info to comment. You had the clutch changed 3 times? Was this to solve the dragging issue or something else, was the flywheel skimmed at any point, have you tried a new flywheel. Have they looked at the finger in the box that pushes the pin that pushes the pressure plate disc? You say everything was replaced. Please specify what everything entails?

yep, 3 times. the flywheel was skimmed(machined-apparently) when the first replacement was done. The current mechanic said he would replace the flywheel but not sure if it was done as when i tested the car it was driving fine for the short distance.

Parts:

New LUK clutch kit;
pushrod;
release bearing;
seals;
new gearbox oil

I will check with the mechanic what else was replaced.


The pushrod went through the thurst plate with the previous clutch kit.

The car is going back to the mechanic for fault finding.

[panic-mechanic]

If the centre plate gets damaged it usually means the pressure plate is not good or that there is an issue with how the clutch cable was set up. Replace the flywheel. They are cheap and if it was skimmed yes - most likely it was done incorrectly. Again no clue as to where you are otherwise I would recommend you to go to Norbrake in boksburg and be done. they know these thing backwards and can probably sort it in half the time anybody else messes around with it.
gearbox oil is definitely not going to solve a clutch release issue so that is sommer a waste of time and money. neither is seals unles you are doing it just because you are there.
Also try sachs - they have a much softer 'feel' to the pressure plate and thus saves the firewall which is another citi issue.