Connect Gen 2, problem after replacing clutch...

[BumblePoo]

I have a SWB Connect, 2015, 1.6 TDCI with the 5 speed (MTX75?) gearbox.

I replaced the clutch a couple of weekends ago. I asked my local garage to do a diagnostic - one of the guys there is an ex ford-tech and told me clutch is gone but DMF sounds fine, so I replaced with a Valeo 3 piece. I've also replaced the hydraulic line that runs from firewall to the slave cylinder input.

When bleeding the clutch system, the clutch pedal springs to the floor with zero resistance, and then sticks there. Almost like it's gone beyond the point it's supposed to. I can hook it back up with my toe, and it springs up. I'm assuming this is due to air in the system, so I've tired bleeding and it's making no difference. I've tried the back-bleeding method mentioned elsewhere on this forum, but there's loads of brake fluid coming through the bleed screw threads for that to be effective, I think. Have tried gravity-bleeding (nothing) and just solo bleeding (with bleed pipe from slave cylinder submerged in fluid).

Have I buggered something up?

[metalworker0]

sorry all i can think of. - flexible hose in the pipeline has failed internally creating one way valve -

you've done everything possible

There are three links to different set-ups

i don't know which one yours is --- please have a look and say which one .

http://www.catcar.info/ford/?lang=en&l= ... gwMg%3D%3D

note link above may not work with windows 7 edge browser

all the best.mark

[BumblePoo]

Thanks Mark.

I'm good with spanners and I'll give pretty much anything a go, but getting the trans out and back in was a bar-steward.

You don't think I might have damaged something in the bell housing when re-fitting? I used an alignment tool but I had to get pretty rough with it to get it all lined up. FWIW I don't think the input shaft interfered with the springplate at any point. Really hoping I can fix this without removing the trans again.

Regarding the brake bleed nipple: I mentioned there was brake fluid coming out via the threads. I only made a 1/4 turn. I take it that's not normal.

[Altransit]

Did you replace the slave cylinder? You might need to replace the master cylinder as well

[metalworker0]

if you don't get it lined up . the transmission will not bolt back on .. there would be a gap around it, something like 10 - 15mm

That's with conventional clutches , Sorry i have no experience of DMF

Possibilities: wrong parts belonging to another model ...

The mk2 connect.is available with 5 speed and 6 speed

The five speed is the mtx75

The 1.5 and the 1.6 with mtx75 share the same bearing part number

The 6 speed release bearing.. different part number looks very similar though!,

checking part numbers

your 1590999 5 speed release bearing also fits mk1 1.8 with mtx75

but mk1 also has one called by part number for 1678165

1827889 is 6 speed

all the best.mark

[BumblePoo]

Yeah. I actually waited til I had it dismantled so I matched up the old part numbers with the new. I was. A bit paranoid about ordering the wrong stuff. So confident they’re the right parts. Bell housing is tight up against the engine case so not worried about that. I guess it just have gone together ok.

[metalworker0]

if you replaced a clutch and assuming its gone of 80,000 miles and to replace the master cylinder would be replacing a consumable item that maybe has got near the end of its life.

all the best.mark