Okay, well I went to VW Listers in Stratford as recommended by Greeners.
You mean you take notice of what he says?
Only joing Nathan!
They were a lot more friendly. Everyone wanted to help out even though I was awaiting a particular service person to get off the phone. He was also appreciative of my problems and helpful.
They've booked the car in for next week (work issues mean I can't do it before then) and they'll give me a loaner (which is more than VW Solihull have done). They suspect the master cylinder as opposed to the slave cylinder. I don't know whether it's because getting to the slave cylinder means dropping the gearbox out or something. The part's been ordered prospectively and they'll see if it sorts the problem out (after ruling out any other simpler causes). If not, they'll have another look.
Hmmmmm . . . . I'm gonna stick my neck out (awaits subsequent shooting down in flames). I really don't think yours is a master cylinder issue. Generally, master cylinders work 100% - or they leak. There is zero evidence of fluid leak on yours. The pushrod which connects the clutch pedal to the actuating piston inside the master cylinder is smooth in operation - and when you do get an element of normal clutch operation - the master cylinder appears to function normally.
Master cylinders, especially clutch ones are incredibly reliable - I'm struggling to remember ever changing one, on any of the various makes and types of vehicles ive worked on.
Me thinks the VW garage is just taking the easy option first, clutching at straws. And not forgetting a nice cheque from VW UK for warranty work.
Then concern is if it's the clutch, a new clutch + fitting would be £900 or so. Even to look at the clutch, they will want my authorisation and will charge if it's not a warrantiable part that needs replacing.
Huh - do NOT agree to make any payment. The clutch is a fully warrantable item - the only way a clutch is not covered under warranty is for 'normal wear and tear'. I can't remember how many miles yours has - but a clutch should last at least 60k miles - irrespective of how powerful or not a car is. For VW to demand payment, they would have to prove that either you had been somehow negligent with the clutch, or that you were say using the car either as a driving school car or a taxi.
If the VW garage still try to insist you make a payment, take the matter up with VW UK Customer Services, and if VW UK are reluctant to play ball - firmly advise them that you will seek assistance from Volkswagen Driver mag and/or What Car - they will soon authorise all warranty work, if they have any sense.
So potential outcomes:
1. Master cylinder swap sorts the problem out
2. It doesn't and the gearbox needs dropping out. If it's the slave, free.
3. If it happens to be the clutch plate that needs to be replaced, £500 or so for labour and £400 for parts. They'll offer 10% discount on both if it's the clutch so £800 or so instead.
Do NOT agree to any discount - at all. By agreeing to discount - you are basically agreeing to pay. This is a warranty item - and you should not have to pay anything. Period.
My main concern is this: swapping the master cylinder doesn't solve the problem but masks it. I run out of the warranty
period (in two months!) and then the same problem recurs. They couldn't advise me whether they would charge but suggested that I'd have to cough up. Despite the fact that the problem has been occuring whilst under warranty.
If you have already registed a 'fault' during the warranty period, and VW fail to rectify it - you have no worries about the warranty ending - the case
should remain 'open'. Though as a safeguard, when you call VW CS, make sure you get a 'case number'.
And I can refer you to an established precident - my old Audi S4 had a very similar clutch problem (pedal going to floor and not coming up) - and this was replaced and fully covered by warranty when the car was 2.5 years old. The clutch friction plate broke up, overheated, damaged the pressure plate and the DMF - all replaced, along with the release bearing - and I didn't have to pay a penny.
Any ideas?
EDIT: The drive there and back was reasonable. I didn't push the car. Occasionally the pedal stuck on the way up but only after the clutch had engaged. Am slightly concerned that they may not pick up a problem either!
If the VW garage tries to fob you off - saying that it is normal, demand that they compare it (with both the stealer and yourself present) with another manual Mk5 Golf (it doesn't have to be an Ed30 - ANY 6 speed manual Golf will do).
HTH