Hey all,
My clutch pedal has been feeling very rough. You would depress the pedal all the way then bring it up slowly and it would stick and feel very rough down the bottom.
After not driving it for over a week it started to squeak everytime i pressed the clutch pedal down aswell!!

Heres the fix...

First remove the Clutch slave cylinder from the side of the transmission housing. There is only two bolts holding this in..


Here is the slave cylinder with the boot and rod removed. There is not need to remove the banjo bolt.


Pic of the rubber boot and the cylinder rod removed. This should come apart from the slave cylinder with next to no force.


When removed you can see that it is slightly damaged and rough. There is a nipple at the top which needs to be grinded down flat. When i removed the rod there was no grease on it.


Grind the nipple down carefully and polish up to a high finish. Should look something like this


Inside the clutch, you can see the release fork and the cup for the slave rod. Clean this out and reapply high temp grease. If you have a dremel with a polishing bit it would make the job alot easier.
The actual boot over the fork can come out with a tug.


Assemble the Slave cylinder with the boot and rod. Make sure there is high temp grease inside the boot and on the ball end of the rod.

Slide the slave cylinder back into the transmission housing making sure that the rod arm ball sits in the cup of the release fork.

Bolt up and you're done! Step on the clutch pedal a few times to work the grease between the joints..

 

I should also add that you might want to lubricate the rod and pin on the clutch pedal side inside the car. This should be done frist as your problem may only be that..

 

Nice! You should post this in Under the Hood.

 

Do you use stands when you are under there dbzerk?

 

Mad if you don't.

 

LOL... i used buckets under the wheels..

Of course!!!
Its a habbit of mine to use the stands on either side and also leave the jack up but not full pressure...

 

AUS: Want to move this to UTH for me??

 

Thanks

 

You the man. This just happened to me in the past week. How long did it take?
This should def be put in the faq and DIY thread.

 

my 2002 had the same problem for a while. i finally kicked the laziness and did the same repair. i just used the dremel on the nipple, no fine polishing and it is super smooth.

and it look all of 15 minutes. it was more of a pain to jack the car up!LOL