I intend to post a longer message later to describe my problem, but in advance of that, can someone describe the mechanical layout of the clutch release mechanism on a 2.6V6. In VERY short, the problem is that what started out as a "clutch needs bleeding" diagnosis on my part has not been the case. Even after bleeding... Clutch doesn't come back up properly on releasing (can be popped up by foot) - although drive is engaged OK. Pressing accelerator (henceforth know as gas for ease of writing) makes clutch pedal pop up. See-Saw action detected - applying slight pressure to clutch pedal and then on and off gas causes clutch to go down (no real back pressure, it just drops) when lifting off gas, but clutch presses back up on applying gas. The above behaviour is detected in gear 1/2/3/5 and R, but not 4th!! Example : Go from 2nd to 3rd: Lift off gas / Clutch goes down a bit (as above) when slight pressure applied, push all the way down, and clutch engages, change to 3rd, release clutch (pedal doesn't return up), apply gas, pedal pops up. Go from 3rd to 4th EXACTLY the same, but on applying gas, clutch does not pop up. I can come on and off gas in 4th, and clutch pedal remains stuck down (about 1 inch off floor). now - two interesting points from this stage: 1) If I pop up clutch pedal with foot, and then press down again, there is really GOOD pressure. Nice weight, engages well etc 2) Remember I said I can come on and off gas in 4th and pedal remains down. If I leave pedal alone, don't touch clutch at all, and slide in to 5th (let the synchromesh do the work), as soon as apply gas, pedal pops up. I suspect if i did the same down to 3rd (with a blip of gas in neutral to help), it would do the same. So - points of note; - My reference to "pop up" is the fact that the pedal is counter sprung - so it compresses the spring on down and up, hence the "pop" is caused by the pedal spring holding the pedal down, and then pulling back up past the mid point. My analysis though is that when the pedal sticks down, there must be no return pressure from the hydraulic system/cluch. - I HAVE bled the system completely. It just doesn't feel like a hydraulic problem now...If it was master cyl., then why is it PERFECT in 4th (good back pressure), and PERFECT when stationary with no engine running. - If it were the slave, same applies really. - Since it affected by on/off gas, it sounds "torsional". I have checked engine mounts/gearbox mounts. they are fine (the car is a 52 plate, 110k miles). There is absolutely no drivechain noise (clonks etc) when coming hard on and off gas in, say 2nd. - There is no release bearing noise So, I'm guessing this must be something going on in the bellhousing (still don't quite understand how the gear can affect this), but since there are no pics in the Haynes guide of the bell housing, and the clutch release assy is all contained within it, with no inspection point, I need some idea of what this could be, or why. I'm more than happy to pop the gearbox out, but would ike to be armed with either clutch kit or release cyclinder assy, and not both, before I do it. Any thoughts would be useful. I really think I've covered everything (I had actually planned on this being an introductory mail to the problem, but it seems to have grown!!!). I'm a more than competent DIY mechanic and have replaced countless clutches on RWD cars.....I think I've seen a good number release mechanisms, cable and hydraulic......but this fault is stumping me. I guess it could just end up being cover plate springs......but why the 4th gear anonmoly!! ........and why would a 3.5 year old car, with 110k have a shot clutch......to do that mileage, generally requires lots of long trips (and I know it was an Exec's car, doing travelling all over the midlands), so it's probably done less gear changes than Mrs Housewifes Corsa with 12k on it. Help!!! Rich
