Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Clutch problem help please!

We’ve just arrived on the Isle of Man and our clutch has started to fail. If I am stationary and in gear sometimes the clutch disengages and the car jumps forward 😣. Sometimes it is difficult / impossible to get it out of gear so I have to brake and stall it. If I pump the clutch pedal a couple of times it seems to work for a short while before the same happens again. I’m not experienced with car mechanics but I’m guessing it is an issue with the hydraulics operating the clutch? I think the 2019 GDi has a master and slave cylinder arrangement? Can anyone offer me some advice on likely problem and does anyone know of a garage on the Isle of Man likely to be able to diagnose/ fix it please? I fear we may be having to get it taken back by the AA🙁. First breakdown in 25k miles of ownership but has to be at the start of a weeks holiday!

Any advice gratefully received.

Thanks

Sounds like a master or slave cylinder failing.

Sounds like you’ve lost fluid pressure. You can check by looking at the reservoir - likely empty/low.

Suspect seals failure somewhere - loose union would be unusual.

You might be able to limp along by regularly topping up the fluid & pumping.

As for garage - I’ve only been to IoM once - google is your friend on that one.

I had the same with my 2019 GDI after 11'000 km. On the bottom of the clutch reservoir I found a fine metallic sand (checked with magnet). I suspect these are machining residues that weren't properly washed out of the holes. They destroyed the gaskets of the clutch hydraulic system.
Replaced both: Master cylinder and slave cylinder under warranty of Morgan. Slave cylinder is a Mazda part (NE55-41-92XA). Master cylinder Lockheed LBACBL018AP. Now fine for another 50'000km.

Well the good news is that your GDI Plus 4 has an external clutch slave cylinder accessible for checking and bleeding outside of the clutch housing.

I would start as suggested above by checking clutch hydraulic reservoir fluid level. Although the reservoir (3) is clear plastic the clear colour of fluid can be difficult to see without taking the filler cap off. If it is low check for leaks on clutch master (2). Screenshot of parts book below to identify parts I'm referring to.



If fluid level is low but no leaks seen in vicinity looks for signs of leak from slave cylinder underneath left hand side of car between engine and gearbox.

Any competent garage should, as a minimum, be able to identify any failed part once car is on a ramp assuming the problem lies with clutch hydraulics.

Found care of AI
PSM Vehicle Services - In Douglas Hills Meadow Ind Estate 01624 677107

Sure sounds like a hydraulic problem. BTW, very few parts of car mechanics are difficult. After all, you already diagnosed this issue and diagnosis is 90% of repair! Let's go further. We merely have to dig a bit deeper.

1. Is there any leaking you can detect? Spread a newspaper under the area of the clutch master and slave. If there is no leaking, you are out of fluid from some leak or a MC internal seal has gone and you are leaking from one side of the cylinder to the other

2. check the clutch fluid reservoir. Is it full or empty? BTW, what colour is the fluid?

I am familiar with the roadside skill set one finds in the UK. I kept a trad there for over 10 years. Whatever you find, any mechanic over 12 will be able to get you up and going in 30 minutes if they have the right parts at hand which you can provide or they can read the #s of the guilty component. You simply have to figure out what is wrong, using the expertise this forum can provide and your own eyes. .

Sadly, I am flying for the next 16 hours. But if you answer these questions, you will be going a long way. (At this point, I usually tell my life partner to go shopping.)

L.

AlyMatt, the symptoms you describe are very typical of the later style master cylinder starting to fail

Check to little plastic header tank & there's usually no fluid loss, that's because the internal seals are bleeding fluid between each other so the loss is only operating pressure sent to the slave cylinder, hence car creep even with the clutch pedal down and snaggy gears

You should be able to see out your holiday by using a couple of pumps to help with gear release & don't sit at a red light in gear with the clutch pedal held down

Good luck

I'm having exactly the same problem, couldn't have explained it any better. I have a 1998 +8 and based in Canada where Morgan has no presence. so, it's down to online shopping.
Can the more knowledgeable members help me out with part numbers for the clutch master cylinder, and I would be better off to replace the slave cylinder too.
Any help would be greatly appreciated,
Regards Dave

All good advice to be found with the above. As said you have the Mazda box which has the external slave on the side of the gearbox. Mazda dealer should help there. All Mazda boxes supplied to Morgan were from Vitesse so a quick call to them to confirm part no. would be a good idea. Main dealers don't seem able to deal with anything you can't supply that for. I'm fairly sure that the box's were not totally standard Mazda either but know no more. The master cylinder would be as Morgan fitted. A repair kit might be possible or ask someone like Lifes motors, They are in southport and could probably overnight one to you or your chosen mech on the IOW. Best of luck, it's not going to be a problem that can't be easily fixed but check you fluid in the reservoir and top up if needed, Think you have a separate reservoir for that system, its a little round one mounted on the bulkhead.... not the square brake one by the servo, big round black thing like a biscuit tin. It will be DOT 4 fluid you need, so Halfords or similar or petrol station. Don't spill it on the car paintwork. it will damage it!