Peugeot HDi -clutching at straws? - dickCD
Travelling about 70mph on the A4 motorway out of Paris earlier this month, the gearstick of my 18 month old Peugeot 406 HDi estate jammed in neutral. After a fruitless hour on the hard shoulder trying to contact Peugeot assistance I finally escaped the Paris rush hour traffic wedged in second gear with a police escort (take back all I ever said about French cops) to a local hotel.
The next day a helpful freelance mechanic (all Parisian Peugeot dealers were closed for vacation!) revealed that the clutch fluid had disappeared out of sight. It hasn't lost a drop since being topped up, but my local dealer here suggests I replace the master cylinder 'just in case' at a cost of £420 (my warranty only covered 12 months).
I don't believe in the supernatural, nor pointless bills. Does anyone have an idea as to what may have caused this, given that the car was serviced 3 months ago?

DickCD

Peugeot HDi -clutching at straws? - bernie
It would be obvious to you if said clutch fluid had dissapeared because there would be no pressure at the clutch pedal.Was this the case ? If no,there was no pressure at the pedal then you would not be able to engage a gear with the engine running(obviously)but the gearbox itself would not be jammed.

It should be easy for a mechanic to spot where the fluid went as it would leave a nice big mess at the point of leak.At 18 months old I would be very sceptical about the need to replace the clutch master cylinder,and anyway was it that and not the slave cylinder ?

If your problem was down to either cylinder leaking,I am sure that a new seal would sort it out,provided there was no scoring to the faulty cylinder.

£420 ? you are being ripped off !
Peugeot HDi -clutching at straws? - dickCD
Yes, I should have been clearer: the clutch lost all pressure, but the gearbox itself was fine. But the mystery of why the fluid disappeared then but not since remains, as no-one found a leak to treat. It may be that the level had fallen over recent months - I didn't check regularly, I admit - and possibly wasn't checked at the last service either. But again, it's supposed to be a closed system, isn't it?

dickCD
Peugeot HDi -clutching at straws? - Dave N
You may well find that your car has the latest 'sealed for life' master cylinder. And they have started tucking these up under the dash with no real facility for refilling or repair. In fact some require substantial disassembly of the dash to even get to it. Therefore, if it's failed, £420 may not be unreasonable.

It's the price you may have to pay for modern motoring. No garage is going to start stripping and replacing seals, as there could be some comeback if it doesn't all work correctly, and they probably don't have instructions on how to do it anyway, that's if spare seals etc are even available.
Peugeot HDi -clutching at straws? - bernie
DaveN
Its a sad reflection on todays mechanics if they dont have the nous to repair something as simple as the seal in a hydraulic cylinder.

I somehow think that this is a main dealer attitude where the majority deal with company cars,the cost of repairs being born by the "Company".

I bet there's many an old motor engineer somewhere in the backstreets who could fix this before breakfast.

Seals for these applications are usually readily available from motor factors .

I think that automotively,you have led a sheltered easy life!
Peugeot HDi -clutching at straws? - Dave N
Bernie
Just telling you how it is my friend. I don't know if it has a sealed master cylinder, just surmising, as a lot of new french cars do, and parts aren't available for them. Sadly, there aren't many 'old motor engineers' anymore, and not many people in business will take the risk of trying to repair things anymore in case it all goes pear shaped. If you were in the trade, as I am, you would realise the insurance and liability issues involved. Not to mention the fact that things are now press fits, riveted, welded, and so on, and don't lend themselves to being taken apart and repaired. I have learnt this the hard way, and to be honest, a great majority of customers don't want to pay you for trying and failing, and don't appreciate the fact that you have done so. Everything has a cost attached to it, sourcing parts, stripping things down, trying stuff out, and all has to be paid for by someone. Many a time I've been asked to do bits and pieces as customers want to save a couple of quid. Even though I point out all the possible pitfalls, and explain in words of one sylabal or less that I still want paying if it doesn't succeed, when it all goes wrong I'm cast as the big bad wolf, reputations get lost, and it all gets messy. It is therefore quite often easier to do it properly, and only do it once, with new guaranteed parts that will do the job as the manufacturer intended, reduced labour time, and safe from liability claims and accusations.

As an example, if you had a problem with your clutch master cylinder, that was a sealed unit and not designed for repair, but you managed to find someone that somehow managed to find a new seal that he reckoned would do the job, so you ask him to do it. Then a week later you go from 5th to 4th to overtake on the motorway and it won't go into 4th 'cos the master cylinder has failed, and someone shunts you up the a***, your insurance company will be on to the repairer straight away asking questions like: Did you use the proper repair procedure? (when there isn't one), did you use the proper seal as recommended by the manufacturer? (there isn't one), what specific training have you had on this particular type of master cylinder (none), and so it goes on. At this point, everyone concerned, including you, would probably wished they had just gone the (initially more) expensive route.

That's not to say that manufacturers shouldn't make this type of thing, and many others, more serviceable, but they don't. Take electronics, they use a 50p chip, that can only be read with a £3000 scanner that contains another 50p chip, and charge £400 for an ecu, and you can't get it diagnosed any place else. The motto is, don't buy their vehicles, keep your old ones, find out what some of the potential costs are up front etc. etc.
Peugeot HDi -clutching at straws? - Ian (Cape Town)
>>Many a time I've been asked to do bits and pieces as customers want to save a couple of quid.

hehe - my first car (68 Cortina) ended up with more bits of wire, old ballpoint pen cases, household flex, tin cans, cigarette packet foil, jubilee clips etc than original parts!
Oh, foolishness of youth!
Peugeot HDi -clutching at straws? - volvoman

Totally agree with you Dave N - my loal mechanic is finding this an increasingly worrying problem - expensive, overcomplicated and unreliable parts which can't be reaired and need expesnive diagnostics. Are the big boys doing this to put the smaller garages out of business I wonder !
Peugeot HDi -clutching at straws? - Dave N
Volvoman, it's a well known fact that dealers don't make any money from selling cars, so it has to come from somewhere else, and servicing is the main area. Plus manufacturers aren't in the business if making cars, they're in the business if making money. The best way to do it is to sell the lowest quality product for the highest price, and to tie customers in for as long as possible. Not to mentioon the fact that most everything is designed for ease of manufacturing by machine, not ease of servicing by humans. Can't really blame them I suppose. The other benefit to the manufacturers is that 2nd hand values get depressed by expensive servicing and replacement parts costs, thereby forcing many to replace uneconomical to repair vehicles into new ones. And of course, the more people that say 'the repair costs more than the cars worth', the better it is for them. What we should really do is compare what an existing vehicle is worth to us, and not what it's worth on the open market, and make a repair decision based on that. You only have to look to Japan to see how cars are almost throw away items, and the mindset is simply to keep replacing them just as you would a mobile phone.

The block exemption rules are supposed to be coming soon, which in theory will give everyone access to technical data etc. But no-one really knows how this will work in practice, if indeed it ever will work.

As I said before though, we happily go and buy the fanciest thing we can lay our hands on, with the most gadgets we can get, and it all costs money somewhere along the way. It will be interesting to see how things change as the number of company cars reduces, as I'm sure this has an effect.
Peugeot HDi -clutching at straws? - Ian (Cape Town)
I 'lost' all the fluid on my BMW once. It was leaking from the top of the master cylinder, and dripping onto the underside of the dash, where it was soaked up by the sound-deadening foam.
Check there, check the carpets (which will need a damn good wash to stop them rotting!) and check the outside for signs of leakage - normally telltale signs are the loss of paintwork!
Peugeot HDi -clutching at straws? - bernie
Ok Dave your point is taken and accepted.

We are being shafted from yet another angle.I think I will open a new thread on the discussion page.

Bernie



Peugeot HDi -clutching at straws? - Arfur
I've found myself in the situation many years ago when the slave cylinder failed. What I was able to do was

1. Stop the engine
2. Place car in first gear.
3. Start the engine. The car will kangaroo until the engine is started properly.
4. Run in first to highish revs.
5. Gently (very gently!) move the gearstick out of first and as the revs die select third gear. Push gently against the resistance you feel and at the right engine speed the gear stick will slide in. If you miss this point you may have to blip the throttle and try again.
6. Once in third keep on driving till you have to stop and then try again.

This was an 85 Carina with no electronics. Readers may wish to comment on the advisablility of this technique on a newer car. This may get you off of the hard shoulder and into a service station which is a much safer place to be.
Peugeot HDi -clutching at straws? - dickCD
Many thanks, all, for your detailed and helpful comments. Once bitten, I now know what to do. For the present, I'm keeping a bottle of hydraulic fluid in the glove compartment in case the level decides to fall again - and would then take steps to find out what needs fixing...