92 9kT sudden clutch failure

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Charles - 09 Oct 2005 03:38 GMT

I pushed in the clutch on my 92 9000 Turbo w/191k miles today and it
went to the floor.

I am not used to sudden catastrophic failure of a hydraulic clutch. The
linkage seems fine, the plunger seems to be going into the master
cylinder, but no clutch. There does not seem to be any evidence of leaks
and the fluid in the TCS/ABS brake reservoir is full. It seems that is
where the clutch fluid comes from?

Any suggestions as to what went wrong?

If it is in the slave cylinder we are looking at $1250 here.

Thanks,

Charles.

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Charles C. - 09 Oct 2005 04:46 GMT

> I pushed in the clutch on my 92 9000 Turbo w/191k miles today and it
> went to the floor.

You mean no pressure on it? It should go to the floor anyway.

> I am not used to sudden catastrophic failure of a hydraulic clutch. The
> linkage seems fine, the plunger seems to be going into the master
[quoted text clipped - 3 lines]
>
> Any suggestions as to what went wrong?

If the problem is hydraulic then

- if it was the slave cylinder it should leak as the seal(s) would have
failed.

- if there is no leaking fluid it should be the master cylinder (I had
two fail on my 900s for brakes, they did so slowly not the way you
describe).

If master works slave is just a piston. If fluid goes in the cylinder
piston goes out and returns from the pressure of the clutch.

If it is mechanical then the pressure (thingie) of the clutch must have
collapsed. You would have heard some noises ... too unlikely.

> If it is in the slave cylinder we are looking at $1250 here.

It should be no different to the price for a clutch job (and if you have
to do the slave you should consider replacing the clutch too).

Sorry for your bad news.
Charles

PS. Read on in case it means anything to you what you got.

Newer 9k, around year 1996 onwards got a modified flexible pipe fitted
between firewall and g/box (GM part). The rubber pipe was reputed to
break down internally and release pieces of rubber which eventually
resulted in its collapse. They blocked the valves in the slave cylinder
and reputedly also damaged the seals.

When it happened to me my then dealer took me to the cleaners (b@st@rds)
and I never got the failed parts back. There was also a story that the
slave itself collapsed.

Whatever caused the problem, a badly designed pipe or a cr@p slave,
before the failure you would get a hard clutch pedal. Harder than
normal even momentarily solid. Well, at some point when the pedal is
solid, you step on it and something gives ... In my case the flexible
pipe burst and then ... I was cleaned. Eventually they lost the
dealership though.

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Charles C. - 09 Oct 2005 05:15 GMT

Ouch, did I write this below?
(Late in the night waiting for the Japanese F1 GP)

>- if it was the slave cylinder it should leak as the seal(s) would have
> failed.
[quoted text clipped - 5 lines]
> If master works slave is just a piston. If fluid goes in the cylinder
> piston goes out and returns from the pressure of the clutch.

If the master cylinder works, then the slave is just a piston. If fluid
goes in the slave then the piston goes out ... etc

> If it is mechanical then the pressure (thingie) of the clutch must have
> collapsed. You would have heard some noises ... too unlikely.

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Charles - 09 Oct 2005 07:03 GMT

> > I pushed in the clutch on my 92 9000 Turbo w/191k miles today and it
> > went to the floor.
>
> You mean no pressure on it? It should go to the floor anyway.

Only pressure was the return spring.

> > I am not used to sudden catastrophic failure of a hydraulic clutch. The
> > linkage seems fine, the plunger seems to be going into the master
[quoted text clipped - 18 lines]
> If it is mechanical then the pressure (thingie) of the clutch must have
> collapsed. You would have heard some noises ... too unlikely.

Funny, there was no warning. It was like a cable clutch, one day, the
cable snaps! Normally with Hydraulic clutches you have some warning,
feels funny, leaks, etc. I looked at the slave particularly and could
see no leaks there. Nor under the car.

> > If it is in the slave cylinder we are looking at $1250 here.
>
[quoted text clipped - 3 lines]
> Sorry for your bad news.
> Charles

Well, as you know, modern clutches have the slave inside the clutch
mechanism, not outside like the 95/96/97 V4's. So you replace the whole
damn thing. $1,250. US dollars in Denver, CO.

> PS. Read on in case it means anything to you what you got.
>
[quoted text clipped - 14 lines]
> pipe burst and then ... I was cleaned. Eventually they lost the
> dealership though.

I never got any warning. I bought this car about a thousand miles ago,
clutch seemed normal until the moment it snapped. That is what has got
me confused.

Thanks,

Charles.

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