Synergie clutch judder, now clutch wont disengage.

[Ianhw77k]

After changing the gearbox mount in my Synergie, I was still getting clutch judder problems.
This morning I went to use it and the clutch pedal felt heavy. After pumping it up and down a few times it got a lot lighter but I can't engage any gears.
I've had a neighbour sit in there and press the clutch pedal down while I look and there is movement, not a lot but about the same as the other day when I did the same check.

Do I order a clutch kit now and get the spanners out? Or am I missing something?

I desperately want to avoid changing the clutch but I need a car in order to earn money, so the sooner I can get to the bottom of this, the better.
The car is a 1995 Synergie with the 1.9td lump in it.

[ken newbold]

It's either the clutch cable or the clutch itself. My guess would be the clutch due to your previous problem with it.

[Ianhw77k]

OK, now I'm going to have to figure out what needs to be unbolted, removed, moved etc.
A couple of years ago my dad had a later model and I helped change the clutch on that, it was a pig of a job! Mine seems to have a bit more room under the bonnet so I'm hoping I don't have to do so much of it lying on my back.

[ken newbold]

Improve access by removing front of car i.e. grille,bumper, lights etc. No need to get gearbox out, there's enough room to move it aside to access clutch. Be sure to fit new nylon bushes on the pivot bolt top and bottom, oh and make sure you fit a quality clutch, valeo etc, not a cheapo. Also fit new input shaft sleeve which contains the seal, held on by 2 torx or allen screws

[Ianhw77k]

I think I'll do that bottom engine mount while the driveshaft is out as well.
Thanks.

[Ianhw77k]

Oh dear, broken fork.

[jgra1]

cheap enough Ian I think.. I bought one for a 206 a few months ago, about £9
I cant remember if I got it from ebay or a dealer, but I suspect ebay..

John

[Ianhw77k]

I'm trying the local citroen dealer first, clutch fork kit on ebay are around £40. Then there's the clutch kit (no point putting the old one back on) and the flywheel is showing me that the crankshaft oil seal could do with replacing.

Is flywheel removal difficult on these things?

[ken newbold]

Nope, you've done the hard bit. The seal should be available from any good bearing/oil seal supplier. Get the flywheel off and you should be able to see it's numbers. there are three, ??? internal diameter x ??? external diameter x?? thickness, might even have one here if you can give me the numbers.

[Ianhw77k]

I've ordered the seal from the local motor factors, around £10 including vat, also ordered a borg and beck clutch kit as they're a name I trust. The flywheel bolts are very tight so I'm going to lock off the crank pulley with a bar and use another bar on the flywheel bolts.

Next problem, I broke the nylon bush on the clutch fork rod trying to remove it! Have you ever tried finding a set of those bushes? I was looking forward to a week of waiting for them to arrive until I found someone in the UK who's got a set.

The local citroen dealers can get me my engine mount and driveshaft oil seals, so that's that covered.

One more question, how do I remove the clutch fork rod on this thing? I've got the pin and arm off, broken the top bush but I still can't fathom it?

[RichardW]

service.citroen shows:


0127 28

01
CRANKSHAFT BEARING SEAL
90X110-7
SFCM -

[Ianhw77k]

Oh yes, do I need to drain the oil first?

And finding a clutch fork for the ME gearbox is another difficult task. I've had to get one sent down from a breakers up north somewhere, I just hope it's the right part.
I have spent literally the whole day on the phone or the Internet, chasing parts for this car. Everything seems to be made from unobtainium!

[RichardW]

And here's the nylon bushes - they're still available at the dealer allegedly:

05

2175 40

01
CLUTCH FORK BEARING
SUP
06

2175 41

01
CLUTCH FORK BEARING
INF

[Hell Razor5543]

Oh yes, do I need to drain the oil first?

And finding a clutch fork for the ME gearbox is another difficult task. I've had to get one sent down from a breakers up north somewhere, I just hope it's the right part.
I have spent literally the whole day on the phone or the Internet, chasing parts for this car. Everything seems to be made from unobtainium!

Just so long as unobtainium is not in the same group as fragilium!

[Ianhw77k]

And here's the nylon bushes - they're still available at the dealer allegedly:

05

2175 40

01
CLUTCH FORK BEARING
SUP
06

2175 41

01
CLUTCH FORK BEARING
INF

Only if you want to wait a week for them to arrive from France.
I eventually managed to track some down in the UK, took a lot of searching.