Brent 89-GT

I have a condition where the clutch pedal does not return to the fully up position . It happens when the car hasn't been driven for a day or two. Once it gets used and the car is warmed up it works fine. This is starting to occur more often than it used to.

I am going to bleed it but it seems to me that air is not the problem if it starts to work after some use. Both the master and slave were new three years ago.

Anybody else experience this? I wouldn't think the master and/or slave would go bad after just three years and 15k miles.

Tom. M

Hey Brent,
Likely air trapped in the master...as everything heats up...the fluid compresses the air stuck at the top of the master cylinder..and pedal operates as normal..eventually on a cold day....the pedal will drop to the floor....I think air trapped there has no way of escaping...

The trick is to bleed the system at the master...disconnect the linkage at the pushrod under the pedal....pull the circlip.....and then pull the piston almost all the way out....and when you see the last oring in there..tilt it down a bit...you should hear and see the brake fluid escape.........and when no more air is coming out..push the whole thing back in...reinstall the circlip...and then reconnect the pedal linkage...adjust it to where there is just a slight bit of preload....

Mine is acting the same way..and I need to get at it.....

Later,
Tom
midlman@rennlist.net
89GT

Brent 89-GT

I put the power bleeder on it and did get some air through the slave. One tip on using the power bleeder on the clutch is to prop up the pedal before starting, otherwise it goes to the floor.

Anyway, I was pretty happy about that until I noticed brake fluid dripping down from above. I have a pin hole leak in the "blue hose" that feeds the master from the brake resevoir. So, I know how the air got in, and I know how to get it out.

Can I use regular rubber hose? Of course I would use fuel line type stuff, or will the brake fluid eat it?

BTW, I may not have found the leak without the pressure bleeder. I still say, that is the best tool I own

Rez

I found the best way to get air out is shove the pushrod into the clutch slave. Unbolt the slave just far enough that you can get your finger on the pushrod in the inspection hole and shove the slave body back in, thus shoving the pushrod into the slave. Once I did this and bled a little, all kinds of air bubbles came out.

hupp

I've recently discovered a new way of bleeding that last bit of pain in the A$$ air out of the system. First, bleed as normal using power bleeder then use the slave cylinder technique - check pedal. Crap, some air still in there. Here's the new bit: With only 2 - 5 psi on the system, open bleeder then have a helper depress the clutch pedal. Close bleeder, release pedal then repeat until the air is gone.

ColinB

Hey Brent!
My 89GT had that 'clutch pedal doesn't fully return' fault for years but you are the first one I've ever heard mention it. You probably find as I did, that you have to lift the pedal with your toe before you can use the cruise control. Bleeding the clutch didn't fix mine but when it went in for service they lubricated the pedal mechanism and now the action is normal (and much lighter). Funny thing was I missed the fault afterwards because with it the clutch pedal was in a more comfortable position for my foot.

Colin
89GT SLate/linen

Brent 89-GT

Well.....replacing that stinking little hose has turned into a typical 928 project, a HUGE PIA. The end on the master is behind the brake booster, no way to get even midget hands on the bugger, not enought to get a hose started on a plastic fitting anyway. So I decide to just go for it. I pulled the brake master and un-bolted the vacuum booster only to find out that there is no way I can get that bugger out of the car without pulling the engine. There still isn't room to get my meathooks under there either. I've spent a good amount of energy cursing the Porsche designers over this one. Way to make the car un-servicable guys

Now I think I will try to remove the clutch master in order to replace this $1 hose.

Any advice on where to go from here is greatly appreciated. I currently on a break, I had to walk away for a while

MikeN

Yes, this is a PIA job. Have done it a few times now and the easiest way I have done it is to remove the master.......as you are now doing.......having two people helps also. Also be careful when you attach the new hose to the brake fluid housing......it is often brittle and can snap pretty easily......don't ask me how I know.

As REZ said.......the easiest way I have found to bleed the clutch is to push the slave rod in all the way a couple of times.......has never failed. Good luck......

Chris Lockhart

Brent, where is the pin hole in the blue hose??? Mine was toast at the top of the hose, so I just cut off the upper portion and used a metal sleeve and 2 small hose clamps to secure the new piece to the old one. It's worked great for 4 years. (knocking on wood) No leaks at all, even when using the Power Bleeder. I know that sounds kinda half assed, but I wasn't going to go through all of what you're dealing with, when the lower section wasn't the problem.

Brent 89-GT

The pinhole was right at the top by the res. I had shortened the hose once before and the hose itself wasn't looking that great anymore. It had dry rot type cracks in it. I might have just used you method Chris had I known how ugly it was going to get. I did not like the idea that a leak in that hose could drain the brake res and cause problems with the brakes too. It was just plain time to do it. The good news is that it is all back together. I also used the opportunity to flush the brake fluid too, something I needed to do anyway.

So now I am at the final step, that little bit of air in the clutch system. You guys keep saying to bleed at the clutch slave. That is what confuses me a little. I always considered the slave to be the one under the car that actuates the clutch, not the one attatched to the clutch pedal in the car. I got it to work once before, can't recall how though anymore. Anyone care to clear up my confusion? Is it the rod in the car I should be messing with, or under the car? If it is in the car, do I need to be ready for a brake fluid mess? Super blue is not going to go well with linen carpets.

Thanks for the help guys