Golf MK4 eating (grinding) pushrods. Help please

[Moosajee97]

Hi all
New to the forum (decided to give it a go after searching and finding nothing like this throughout the internet)

So the problem I'm having is that my MK4 Golf 1.6 SR (02K Gearbox) is eating the pushrods. Basically what happens is the pushrod somehow melts the plastic on the release/thrust bearing and embeds itself in there. After I pull it out, I find that the pushrod is noticeably shorter than it should be (2-3 cm). I've already gone through 3 pushrods and release bearings.

The car initially wouldn't go into first while standing still. Then it became worse as it started dragging the car when starting in first. Then it eventually wouldn't shift at all. I redone the entire clutch system. New clutch kit, master and slave. Rebled system. New rod and bearing too. I initially put a cheap clutch and pressure plate in, and thought it was perhaps the cause.

I replaced the realease bearing, clutch plate and pressure plate (Valeo) and even replaced the finger that pushes the bearing. Still no change as it drives for less than 50kms and starts eating the rod again.

It appears to make a rattling/squealing noise when in gear and neutral, but the noise goes away when I press the clutch pedal in

Please help as I am at my wits end.
Thank you all in advance

[panic-mechanic]

almost impossible to comment without actually seeing the box. Almost sounds like oil is not getting to the bearing.

[Moosajee97]

Thanks for your response

Could this be caused by low oil level in the box?
I don't have any pictures at the moment, but the box is very similar to the MK1 boxes.

[panic-mechanic]

It could be yes. I know the box in question yes. Hydro activated clutch but 020 setup. Again, without having a look at what is there it is almost impossible to guess.

[Donavan]

Had the same issue on a friends car after he installed a new clutch kit.

When I had a look, it turned out that the disc that the push rod pushes against that fits into the pressure plate was intalled the wrong way around.

He had excatly the same symtoms that you described