Fitting hydro clutch in mk2 with engine in bay?

Have you got any pics of your set up??? I'll try and get a couple of mine over the weekend and post them up....

Mine was very hard to get on as the cable did seem to be a little short..... iirc i used a big screwdriver to force the arm up enough to slide the cable on. I had to attach it via the gearbox end also.....

I didnt think that cable has expanded much either.......

 

Sounds like yours is set up just like mine. I think that the cable isn't quite long enough, and im gonna have a go at modifying the small tube mounted in the top of the bulkhead where clutch cable goes through, see if i can make that end of the cable move closer to the hook on the pedal (if you see what i mean) so the cable has a bit more length to adjust itself

I also reckon that the clutch bite point is a bit low on mine (not sure if you think the same bout yours) and thats why were havin problems engaging some gears and why the clutch feels a bit grabby.

Also, do you find sometimes that when you give it some on the loud pedal and you change gear that the clutch almost doesn't release quick enough? I often get that and the only way i find to help it is by pressing down the clutch as quick as possible, which again points to clutch bite point being too low

Let me know what you think, and ill get some pics up too of the gearbox end of the cable so we can compare

 

Right Damo, here is the gearbox end of the cable. Its pretty much tight but the adjusting mechansim hasn't even mover out to its first rachet position yet, so as you said with yours there a ******* to fit

 

If it helps here is the hydraulic conversion I did:

you will need a Passat VR6 or Corrado pedal box-



I dot punched the position of the clutch mc so I could see it clearly from the bulkhead



Then it was a case of taking a hammer to the bulkhead



drilling the appropriate holes



and tidying up



before assembling



full details of my conversion can be found here: http://s130.photobucket.com/albums/p271/20vt_project/

Nick

 

Cheers mate thats very helpful. Just out of curiosity, what does the clutch feel like to use now with it being hydraulic (how does it compare to standard mk2 clutch systems)? Mine does work ok with the cable on the 02A but as mentioned in posts above, its just a bit awkward to use sometimes.

Also, whats your opinion about doing the hydro conversion with the engine in the bay, do you reckon you could flatten the appropriate part of the bulkhead from inside the car?

Cheers

 

Here is mine.... sorry for the crap quality.... The cable does look like its extending out a little but its very very tight. I'm thinking of taking it off tomorrow and trying to grease it up a little to see if that makes any difference at all.....

 

Yeah give it a try Damo. Like i said, im gonna try and get the outer part of the cable closer to the hook on the clutch pedal, hopefully to free up some of the cable inner so that the self adjusting mechanism can.... well adjust properly

 

damo i have the exact same problem too..

my clutch sticks quite alot of the time, and i often crunch gears..

personally i dont think changing the clutch will solve anything apart from making it feel nicer, if i knew any better at the time of doing my bloody conversion i would of used a mk4 shifter which would solve properly all my problems, with a hydro clutch, so i have a light feeling pedal..

i struggle to get into 1st gear alot of the time, and sometimes 2nd and 3rd can feel funny, 4th is good, and 5th is ok, but doesnt feel great.

my reverse gear is no better tho, i push down, then have to push along slight go down then up to get it in??

i think its coz my shifter aint setup also i think its down to the crappy mk3 cable shifters which are ****...

i got a seat clutch cable, it feels ok, but it often sticks, and is heavy...

 

Shifter needs alignment. Clutch sticks as you still have that heavy return spring installed on pedel box. This is what makes the clutch feel heavier than it really is.

 

Yeah sounds like your gearstick isnt allined correctly tbh Ben though i dont necessarily think sorted it would solve all your problems. Ive noticed that mine occasionally hard to get in 1st and 3rd sometimes but then other times its fine It crunches reverse 50% of the time and 5th depending on how fast im going.... usually the faster im going the more it cruntches....

Imcoming to the conclusion that its a combination of the ****ness of the 02a and the cable shifter and the crappy SEAT clutch mehanism

 

Toyo: Can't remember what you said now but have you got the seat cable on yours too, or are you using the 1.3 cable? Just wondering if your self adjusting mechanism has actually adjusted out or not

Like you said Damo, mine also crunches reverse 50% of the time, and can occasionaly be a b*@ch to get into gear. Thing is though, the set up is just like it was in the Ibiza from the factory, and surely it couldn't have been this bad when it rolled out. Maybe there also isn't enough leverage on the mk2 golf clutch pedal, therefore not pulling the cable enough so that the clutch isn't releasing properly, making it crunch and difficult to get into gear.

I think one of us needs to get stuck into a hydro clutch conversion

 

you say that tho i've done it a fair few times....

am i doing something wrong? i thought its a case of undoing bolts and getting gear stick as level as possible. then do them up?



i know it isnt properly the aligned up.. but what i was trying to say was... i drove a mk3 16v.. and the gears still felt crap to be honest..

a mk4 shifter is gear change porn

when i put my 20vt in, im using a TDI 02a box with a tt shifter and hydro clutch with LSD.