Getting locked out of gears

B6/7 S4/RS4
#1

Thought I’d start my own thread to avoid threadjacking Axel’s :slight_smile:

I finished breaking in my stage 4 clutch so I did a few pulls.

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

I did a pull a few nights ago, 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.

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

Also, from a full stop when putting it in gear, the car kinda bumps forward or shudders. I can exaggerate the issue by doing an in gear pull to high rpms. This causes almost all the gears to be locked out until the car and rpms slow down. The issue is non-existant when the car is off - I can get into all the gears very easily.

The slave and master cylinders are new (USP) as are the lines. I’ve tried bleeding the fluid and have had no luck.

Short of pulling the clutch and everything out again, is there anything else I could check first?

This is my second JHM clutch. My first had been sent back for warranty for other issues. Both were broken in well past the recommended city kms. I do not ride the clutch or otherwise use it sloppily. Both had under 10 launches with launch assist (in fact I’ve only done two on the new one).

There seem to be numerous issues tracing back to the RS4 pressure plate with both stock and modified clutches. If I end up biting the bullet (again) and pulling the clutch, what other alternatives do I have?

I’d personally rather wait for this new stage 5R pressure plate from JHM if it’s not based on the stock RS4 pressure plate. But at the same time, I’d rather not drive with a clutch that isn’t releasing fully. I can control the minor wear on the clutch to a point by keeping it out of gear whenever the clutch is pressed, but this is putting some serious wear on my synchros.

I’ve been looking around at alternatives that don’t use the RS4 Pressure plate. The clutch masters kits had some issues. The Spec kits seem ok. And the Sach’s kit seems to want you to use their flywheel.

I still have my stock pressure plate and clutch lying around too. I must have done around 50 launches on that thing and had no issues where the clutch didn’t release fully.

Anyways, forgive my ranting. What do you guys suggest the next step should be?

#2

Sounds like maybe waiting for the new R pressure plate might be your solution. Not sure if it’s mine as my symptoms are slightly different than yours. I can’t really push my car at the moment making the supercharger pretty much useless (that and the hot intake temps from the summer season).

#3

JHM recommends opening it up and re-torquing the pressure plate bolts.

Dropping it off tomorrow to get it done.

#4

Why was there a problem? Is that part of the install process…and it just wasnt done the first time? Or is this something that should now be done BEFORE install, and was not in the instructions before?

#5

Or is this something that was possibly done but the bolts got loose? I keep hearing about bolts needing re-tightening but I don’t know if they’re the same bolts.

Do you have to remove a lot of crap to get to the bolts?

#6

Apparently the bolts can get loose. The cause of that, I’m not sure - could be bad install?

The instructions indicate exactly how to install them, and the installer says he followed them exactly (both times).

I’d assume it’ll require a tranny drop to get to it. I’ve asked him to retighten and reset the SAC then to do a few pulls and maybe a launch with LA to see if its fine.

#7

the whole trans

#8

Make sure the right loctite is on those bolts and a good amount

#9

Yup, that was the first thing I mentioned to the installer too, and he says he installed it with a good amount of red loctite. Always worth a re-mention when I drop it off though.

#10

The first pressure plate was found to have warped. Either it was warped from the factory or warped because of improper install.

As for the second pressure plate that had been causing my current issues…

http://i.imgur.com/f2Uttfe.jpg

http://i.imgur.com/LzC1QWK.jpg

I had the shop put on the pressure plate from my stock clutch after cleaning up the friction plate.

The only other thing done was to reset the SAC like is normally done. No other parts were swapped. Install was done the same way as before (JHM instructions)

The issue is completely gone, however I have yet to really push or launch the car other than a pull from second into third, and a few in gear 2nd gear pulls.

I want to give the pressure plate side of the clutch some miles to break in before any launches.

#11

Rivets -can’t live with’em, can’t live without’em. What a bitch. Wonder what is causing them to pop.

#12

Does the metal look slightly deformed on the underside of the popped rivet? ???

#13

http://i.imgur.com/UxyH7fX.jpg

#14

http://forum.rs246.com/viewtopic.php?f=35&t=104900

Relevant? (Can’t be arsed to quote as it’s over multiple posts lol)

#15

That sounds more like Axel’s issue than mine. I’m pretty sure the reason I had a hard time shifting was because the clutch didn’t release fully. You can see the pressure plate is darker just before the rivet.

Whether the rivet popped out because of the rubbing, or whether the popped rivet caused the rubbing? I’m not sure. In any case, JHM made things right.

Hopefully Axel gets his issues sorted out soon as well.

#16

Nah, not my issue. My pedal only sticks after a WOT pull. I’ve been daily driving it for 16 months now lol