Folks,

2004 MCS, 6 speed manual transmission.

I replaced the clutch a few months ago, and since then I've had some issues shifting. Specifically I'll put it in gear to have it pop out of gear. I replaced the clutch slave cylinder a couple of times due to screw ups of my own. I replaced the master cylinder as well. I have bled the system at least a half a dozen times following all of the suggestions commonly listed here. It still seems to be behaving like there is air in the line. It seems to shift ok and stay in gear when the engine is cold, but after driving for a while, it's starts popping out of (or really not being entirely in) gear more often.

To my point, when I replaced the master cylinder, the line from the reservoir (on the supply side) has a rubber gasket/fitting that had a tear. The master cylinder didn't come with a replacement for that gasket/fitting, and I put the torn piece back in, thinking that if it leaked, I would deal with it, if not, it might be ok. It's not leaking fluid, but I think it may be introducing air into the system.

Does anyone know where I might find this part? I haven't been able to find it listed on any parts diagrams, and I'd consider just replacing the supply side line, but since it's not called out, I don't have a guarantee that it would be supplied with a new line. What are your thoughts?

Thanks in advance for your help.

Cheers,
Duane

 

Try partsgeek.com.

 

Here you go...

R53 Clutch Control

Not sure exactly which part you are after, but the whole system is shown. You can see which part it is and what is available.

 

Ok, I'll try the new line. I'll let the thread know if the new line comes with a new nipple.

Cheers,
Duane

 

I'm having trouble imagining a hydraulic failure mode that pops it out of gear. Any air in line will make it so it's hard to fully disengage the transmission, which can make it difficult or impossible to shift, but when the pedal is out the clutch should be fully engaged.

I'd start looking at the mechanical linkage, not sure if it's possible for the throwout mechanism to hang up somehow. Check your shift cables, maybe you're not fully in gear.

 

I'll definitely look at the linkage. My current theory is that it's not making it entirely into gear, and that's because the clutch isn't entirely disengaging. The typical symptom is that I'll put the clutch in, change gears, and when I let the clutch out, it pops back into neutral. Usually when I try to put it back into gear after that, it grinds.

Cheers,
Duane