Clutch issue is starting to get gradually worse

B6/7 S4/RS4
#1

So, 16 months after my first “incident” of my clutch pedal sticking after a WOT throttle pull (3rd gear), things are starting to get worse.

Now, if I do a WOT in 1st or 2nd, the pedal typically bounces back really hard (sometimes it gets stuck but usually bounces back), and a WOT pull in 3rd or 4th, the pedal usually gets stuck instead (sometimes it bounces back instead but it usually gets stuck). Now, on top of all that, I can’t go into a gear afterward. So if I do a WOT 3rd gear pull and try to shift up to 4th, I can’t. And I can’t get into any gear until I pull the clutch pedal back out and let the car coast and the revs slowly drop back to a more “normal” range and then I can finally put the car in a gear.

Wtf??? This is really starting to get annoying and not a single freaking person has been able to figure out wtf is happening…sigh…

#2

I recall you’ve tried a few different things to attempt to fix the issue, can you post a brief list to jog everyone’s memory so we don’t suggest stuff youve already done? age of the fluid, bleed the system, age of the clutch/pressure plate/ etc.

#3

I’ve freaking spent over $2000k in parts and labour to no avail.

Replaced master cylinder, replaced slave cylinder, replaced line between the two with a braided ss one.
Replaced throw-out bearing, flushed the system over 5 times (each time with high temp fluid), took apart the system twice to check on all the bolts (once just to check on everything, another when replacing the bearing).

And finally, just recently did a transmission fluid change.

The entire system is from November 2011 when I installed the JHM stage 4 clutch, lwfw (and pressure plate).

#4

High probability that it’s your pressure plate. Happens on the RS4’s more frequently than the S4’s, but since the Stage 4 uses the RS4 pressure plate it creates the same situation. A couple people have had rivets come out recently. Unfortunately you’re probably about $1,500 in labor/parts from fixing your issue. May make more sense to wait for the revised pressure plate JHM is planning for the RS4.

#5

That’s what I’m leaning towards as well. Anyone know if the RS4 pressure plate issue also causes to not be able to go into a gear or only causes the pedal to get stuck?

#6

http://www.schaeffler.com/remotemedien/media/_shared_media/08_media_library/01_publications/automotiveaftermarket/brochure_1/downloads_5/luk_schadensdiagnose_traktor_en.pdf

Decent reference guide for diagnosing clutch issue.

#7

I have seen a few people having pressure plate issues lately…or pressure plate derived issues.

JHM re-invented the wheel a little with their supercharged RS4 setup, using a new pressure plate design/modification. I believe AMD did as well…modified OEM pressure plate.

Not sure what the deal is, but it’s really annoying as an RS4 owner…and I can only imagine how annoying it would be if it’s much worse as it sounds like it is for a few people with aftermarket clutches.

#8

what ever happened to your buddy Jabroni? He was getting an R8 tech to ‘fix’ his sticky pedal issue? was this just the usual ‘stainless line’ b.s. or did they actually do something to fix it?

I have found you can bring on this issue by doing a pull in any gear, getting to or near redline, and then just pushing the clutch in to coast. The stickiness will happen. The clutch will then be stuck halfway or will become really stiff

You can also do it while sitting parked in neutral or in gear with the clutch depressed, and rev it up to 8000 . When you next try to engage the clutch it is stiff as fuck.

#9

Background info: JHM stage 4 with LWFL. was doing pulls with another rs4 member after havjng the clutch installed for 20k miles and the pedal did its first “stick”. This was october 2012. So i did a few more pulls and more stickiness came. So I didn’t worry about fixing it considering I was still able to do pulls and still shift. OK. so recently, 40k miles later the pressure plate starts to act up. Any shift past 3k rpm would grind… WHY? Bc the clutch was dragging. No matter how hard I push the pedal to the floor it wouldn’t disengage… So time for a new stage 4 clutch from JHM. Here is what my clutch looks like after 40k/1 year. Only the outter part was engaging on the disc as shown^ why? Maybe because the rivet backed out? Also notice the difference in color right in the same spot that rivet backed out. Caused it to maybe be uneven? And grab more there then anywhere else. Regardless the clutch still has a shit load of meat. the inner side of the clutch still has that brand new clean look to it.

http://i1025.photobucket.com/albums/y318/rs4tony/null-14.jpg

http://i1025.photobucket.com/albums/y318/rs4tony/null-15.jpg

http://i1025.photobucket.com/albums/y318/rs4tony/null-16.jpg

http://i1025.photobucket.com/albums/y318/rs4tony/null-17.jpg

friction plate ^

http://i1025.photobucket.com/albums/y318/rs4tony/null-18.jpg
only engaging on the outter edge?

http://i1025.photobucket.com/albums/y318/rs4tony/null-22.jpg

I changed all internals as well

http://i1025.photobucket.com/albums/y318/rs4tony/null-23.jpg

http://i1025.photobucket.com/albums/y318/rs4tony/null-24.jpg

Here’s where I think the problem lies, that rivet backed out.(bottom left)

#10

Sorry not 40k miles after the first sticky pedal I had, but 20k miles*** there is 40k on the clutch itself. Cars been launched at 3k rpm about a hand full of times. No more then 10. I know how to drive stick, I’m not a dumbass. It’s not driver error either.

#11

Did you notice any clutch slippage or less grip/bite? I’m asking because my clutch still grabs like a mofo (i.e. the same as when it was first installed). It’s never lost that grab.

#12

Nope never lost grip. Back when I had my stock clutch on my car, it would slip like crazy when the pedal was stuck halfway.

#13

Interesting. So in the end, it was just a rivet that had backed out?

Also, did you ever have trouble engaging a gear after a WOT pull? I don’t get any grinding like you and I can shift at 5k+ rpms no problem as long as it’s not a full WOT pull. If I slowly go up to 5k+ rpms, I can switch gears fine, clutc pedal doesn’t stick or anything. It’s only if I start the WOT pull from below 4k rpms and punch it and let the revs go up to 6k rpms and above.

#14

Got an email saying send it in for warranty inspection. Fingers crossed here. Keep you guys posted.

#15

And yes it was hard to get into gear bc (from my understanding) is that the clutch is still slightly engaged so pretty much you forcing it is just a hair short of grinding. Not good for syncro’s. put it in 1st gear, rev to 6k with the clutch to the floor. Does it roll forward?

#16

Good test. Will check.

#17

I’ve got a similar issue Axel. I finished breaking in the clutch so I did a few in gear pulls.

Basically feels like the clutch isn’t releasing fully. Still grabs hard though.

I did a pull last night in 3rd, then fully let go of the gas and pressed the clutch all the way in and coasted. There was still some grabbing as the RPMs came down.

Also, from a full stop when putting it in gear, the car kinda bumps forward. Then when you rev it it moves ever so slightly forward.

#18

It sounds like your problem is identical to Tony’s. I don’t recall any minor grabbing but I’ll to the test just to be sure.

#19

I do not have this clutch, but a customer of mine, you guys probably know the car, the widebody RS4, he has a similar issie happen, had a few rivets fail, he ended up getting a southbend right after the clutch failed, he literally beats the piss out of that car, auto-x’s it alot!

He did mention last time I was talking to him that he found the JHM pedal wise to feel exactly like stock, although the grab point was crazy strong, he said he even felt nervous, pulling out into oncoming traffic because of how it grabbed, he although did not have any sticky pedals, he did have the metal slave upgrade and stainless lines, now with the southbend he said grab point is like OEM, although it feels crazy heavy to push down, and so far has he not had any sticky pedal issies, I’ll keep in contact with him and report back here.

#20

Here’s a video of one of the pulls I did. Basically coasting in gear with clutch pushed all the way in.

https://www.youtube.com/watch?v=WfAgDmO_-XE