Golf IV R32 :: 02m Clutch Does Not Slip In Any Gear


Oct 11, 2015

So long story short, my clutch is not disengaging all of the way, but only sometimes.... I have replaced clutch, flywheel, slave cylinder, new stainless steel clutch line and new clutch master cylinder all within this month. The same issue has been occurring prior to replacing all of this and also after replacing all of this. I've bled the system (with a power bleeder) more times than you can count on both of your hands so there is no way there is air in the system.

More details : The clutch doesn't slip in any gear. Stop and go traffic in first gear is really the only time I notice it not disengaging. I can't pull it out of 1st gear when it happens so I have to shut the car off to get it out of first gear. When it's stuck in first gear with the clutch pushed in (on a flat surface) and I let off of the brake the car creeps forward. Not at full speed like if I were to release the clutch pedal all the way but its still semi engaged enough to make the car move.

Replacing everything theoretically should have fixed all issues, but it hasn't. The only thing I didnt replace was this piece of the factory clutch line.

Tomorrow I am going to take the stainless steel clutch line and run it straight to the clutch master cylinder bypassing that weird silver box and hope that fixes it. As a side question what does that silver box do anyways?

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Had to get towed to the nearest dealership... at least I got to try out the carnet feature . Basically it is a glorified operator who will request a local tow truck for you. FYI.. I thought that the service would at least notify the service dept at the dealer it was being towed to (nope!). 5 hours later they gave me my car back saying that the cable between the ECU and DSG had come loose and that was the only problem.

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What I'm wondering is, should I just drive it like this until it really starts to go, or should I replace it now? And what are my options for a new clutch? I don't want to big turbo this car, so the most it could get is a few more bolt-ons. I'd like a stock feeling clutch.

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Mileage: 43,000 km
Software: UM stage 2 loaded

Related mods:
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- Emmanuel design, Sachs SRE stage 2 SMf clutch kit
- Tyrol sport deadest rigid collar kit (probably not related)

Background info:
Clutch installed at 40k km.
0-500km stop and go traffic
500-505km punched it bc a 350Z pissed me off*
506-1200km highway and not very aggressive twisters
1200-3000km hwy and city mix

First 0-500km I babied the clutch. No issue
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- re-bled the clutch (no topping off the clutch lines)

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All of my other cars had manual transmission so it's not my driving skills and I don't beat on my car either. My last 2002 GTI had 150,000 miles on it when I sold it and 140,000 of those were chipped. Never once did that clutch slip.

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My guess is I need a new clutch master cylinder. I have plenty of fluid in there although its a bit old so I'll be changing that when I change the cylinder. Could it be the slave cylinder? If so is it a bear to change that? (do I need to drop the trans?)

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