I have a 04 reg 1.9ltr Octavia Elegance TDI with 182k miles on the clock and have recently started to experience an intermittent gearbox fault - occasionally difficult to change gear even when the clutch pedal has been fully depressed. Clutch pedal drops after having changed gear. Clutch travel is soft for first 1/3 to half of distance and then is firmer for the remainder. With the car imobilised in this state I restarted the engine and the problem cleared.

I'm being told that clutch, dual mass flywheel and master cylinder need replaced with an estimated cost of £1,200. This is more than the car is worth and I wonder whether there's any chance is might merely be the master cylinder that has gone or a clutch fluid leak. Linkages to gearbox all appear to be sound and move smoothly. The engine itself runs very smoothly and I haven't noticed any clutch slippage.

Loath to scrap what might be a perfectly good car on the basis of an incorrect diagnosis. I have watched a number of YouTube videos about clutch problems and what I'm experiencing doesn't seem to tally with what they say one should be experiencing.

Does anyone have any suggestions as to how I might determine the true source of the problem or alternatively is there a Skoda gearbox/clutch expert close to GU15 that someone could recommend.

3 hours ago, Quilleron said:

Clutch pedal drops after having changed gear. Clutch travel is soft for first 1/3 to half of distance and then is firmer for the remainder. With the car imobilised in this state I restarted the engine and the problem cleared.

This is a bit unclear.

Can you explain a bit more

Do you mean that the clutch seems to not disengage properly?

3 hours ago, Quilleron said:

wonder whether there's any chance is might merely be the master cylinder that has gone or a clutch fluid leak.

Id agree.

Have you checked fluid level and for leaks?

If there is a leak, the fluid will be lower and or you will see the leak or dripping fluid.

Next time it is difficult to change gears, try pumping the clutch a few times quickly. If that helps it sounds like master/slave cylinder issue

Thanks for your prompt reply and help BlueWagon.
Checking the clutch travel and pressure; it seems fairly normal, about 1/3 quite soft and then harder for the remaining distance. I have tried pumping the pedal but that doesn't make any difference either with or without the engine running.

After having changed gear while moving the pedal softens and feels as though it is dropping away.

As mentioned, the problem is intermittent, disengaging from the gears not a problem but re-engaging into either a forward or reverse gear is.
Just now, with the engine running and while stationery I can change into any gear.
All somewhat mysterious...

Sounds like either master or slave failing and letting fluid past seals. Had same on my 1.9tdi. Random clutch to floor and wouldnt come back until I lifted pedal with foot. Only did it once in a blue moon and no fluid loss then one day clutch to floor and that was it. External seals had gone on master but couldnt see any leaks until it got winched onto truck and fluid drained out of engine under tray. Check the fluid level. If its ok then maybe a clutch bleed in case its drawing in air but it does sound like a master/slave problem. I took master off put part number into Amazon and got a new sachs one £42-00 about half the price I could get one locally. Not the easiest thing to get to. If your fitting it yourself there is a rubber grommet seal that normally sticks in old one that needs to be swapped over or replaced. Its easy to miss

Alasdair

14 minutes ago, Quilleron said:

After having changed gear while moving the pedal softens and feels as though it is dropping away.

To me, that would sound like some sort of leak or, pipe expanding.

The reason they quoted so is due to the recommendation of the doing the DMF while the clutch off. By the time you've factored in the prices of the clutch kit and DMF it won't be far off the price with labour. Of course, shop around. The price does seem a little high to me, I would expect more around the £600-£800...

Now, if the car worth it to you and you're going to keep it for a while, then I wouldn't be put off by doing this. I don't really factor things like this in with the car, as with every car it will need doing, just like routine maintenance. Or, I would've got rid of so many cars... This is my personal opinion.

If the pedal is dropping when under pressure it may be the fluid passing seals but not leaking on master/slave. . On mine 58 plate the slave is external but the rod that activates clutch is internal with rubber gaitor so any leaks end up in bell housing. It can be replaced without Gbox removal. My slave looks like this

Check for leaks at master and if none might be worth removing slave and replace anyway. A replacement for master was around £40 and the slave was around £20 so not the end of the world and worth trying. Its only two bolts and a push clip join.