[Mk2] [Turbo] Clutch fork / release bearing broken?

[PeterRST]

"I think we're in a bit of a Kerfuffle here..."

I refurbished my clutch slave cylinder today. All went really smoothly. Except that now, the clutch fork feels like its blocked. I can only move it about 2 cms and thats it, no "spring" feel or anything.

To make matters worse my dad cranked the car over. Cranked fine first but on second attempt you get that starter motor clicking like with an empty battery so I guess clutch/flywheel are somehow jammed.

I'm now waiting to get a place on a ramp to take the gearbox off. Any ideas what could be the culprit?

[b16hbg]

Take the bottom rubber cover off the gearbox and have a sneak peak. Maybe the release bearing has got stuck to on the shaft? Big job to remove the gearbox have a look first through that hole. Try putting it into gear and rocking back and forth, might free up the starter motor from the ring gear. If it moves freely then you know you have a starter motor fault as well.

[Slarty]

First thing would be to try and jump start the car. You'd feel rather foolish if you dropped the gearbox only to find that it was a flat battery.

Also, were you trying to move the clutch fork by hand? If so, I don't think you'd be able to actuate the clutch with it, they seem to be quite heavy if I remember correctly.....

[b16hbg]

Sarty is right, you wouldn't be able to disengage the clutch by hand at the clutch fork unless you're jeff capes! It takes a lot of force hence you have the leverage of a pedal. Good luck let us know what you find

[PeterRST]

Nah, I used a crowbar and also the clutch slave cylinder. With the latter in place, I wasn't able to depress the clutch pedal fully unless I'd have applied stupid force.

Battery is charged of course.

I looked into the clutch fork hole with an el-cheapo endoscope and I found fresh markings on the inside of the gearbox bellhousing.

Definitely gearbox-off time now. Clutch was probably on its way out anyways so I don't feel particularly bad.

Will keep you all updated with my findings. I guess the release bearing or something in the pressure plate has disintegrated. Probably while I was bleeding the clutch...