In the automotive world, maintenance and replacement of worn parts is a common practice to ensure the performance and safety of the vehicle. However, even after seemingly well-performed interventions, new problems can arise that pose challenges for both mechanics and vehicle owners. A case in point is the 2009 Audi A4 (B8) 2.0 TDI, which was fitted with a LuK RepSet DMF 600014400, and which subsequently developed clutch pedal problems.
The specific problem reported is that, after replacing the clutch kit and flywheel, the clutch pedal does not reach the end of its travel, becoming very hard towards the end and, in some cases, preventing the engine from starting due to the failure of the position sensor on the clutch pump to activate.
This can be particularly frustrating for the vehicle owner, especially considering that the replacement kit was installed to address pre-existing clutch grabbing issues when starting and idling noise. Despite the intention of improving the vehicle's performance, a new set of problems has been introduced instead.
One possible explanation for this problem is the clutch release fork. In vehicles such as the Audi A4 (B8), the release fork has undergone design changes to reduce engine noise at idle and improve clutch actuation. If a new release fork was installed during the clutch kit replacement without replacing the carriers with those to suit the new design, this can have a direct impact on the symptoms you are experiencing.
The old supports, in fact, are not adequate for the new release fork, causing an oblique action and a position further away from the clutch cylinder, resulting in a reduced pedal travel and greater difficulty in starting the engine. The harshness near the end of the clutch travel is due to the limited movement capacity of the slave cylinder.
To resolve this issue, a thorough overhaul of the clutch release system is essential, paying particular attention to the release fork and its supports. Only by adapting these components to the updated design can you ensure that the clutch functions properly, thus avoiding further inconvenience and ensuring the safety and reliability of the vehicle.
