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  1. Siva
  2. Service & Maintenance
  3. Tuesday, June 05 2018
I have an i20 2013 Petrol model driven 48K. Last week i traveled in a hilly area with full luggage load (Occupied 2nd row as well) . Unfortunately there was some accident in the hill road and traffic piled up for more than 5 kms. I drove inch by inch in 1st and 2nd gear, some places i used handbrake to avoid car going back and then released clutch & handbrake at the same time to climb the road. I am not a superb driver, just learning the skills.:(

Because of this, my clutch overheated, become very soft, sticky and stopped engaging gears at some point, simply RPM raises but car does not move. I observed the burning smell as well. I stopped the car for 10 minutes. Started again, now car is able to move but clutch not as normal, It was too sticky. As it was late evening and hence i don't want to get struck in hill, so i drove the car for another 25kms with this problem and stopped on a safer zone.

Searched for a mechanic but not able to find one. It was almost 30 mins i stopped the vehicle now. I thought let me take the vehicle to my home (another 150kms) then tomorrow get it to the service center. But now when i started the vehicle, surprisingly the clutch become normal and i don't see any problem in engaging gears. On next day also, i dont see any problem, so i did not take it to service center till now.

I shared the same with my friends and they advised to change the clutch plate as it may troublesome in future. Can you please clarify me few things,

1. Clutch overheating and back to normal, Is it an expected one or advisable to change the clutch?
2. If i have to change the clutch, how much it may cost?
3. Is it covered under insurance (I dont have zero dep)
4. I am the second owner, when i enquired with first owner, he said, he has changed the clutch once around 20K as he drove the car in water slogged area in 1st and 2nd gear which resulted in clutch burn. Hyundai service center mechanic as advised to change the clutch and it was changed. I have cross checked and it was an genuine replacement.

Thanks in Advance.
Admin Accepted Answer
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Hello,

Clutch Heating is a rare phenomenon
Its like, unless driving real bad then only clutch gets heat up
For Hill drive - In such cases - one can put car in 1st Gear - and release Clutch without a need to actually press accelerator
If driving in a way with Hand-brake up, pressing accelerator and clutch pedal simultaneously - the Clutch gets slipping beyond a limit impacting the clutch with much faster wear

Now as you observing that the car is okay

Suggest to take an early morning drive tomorrow and drive at
> slight higher speed
> Pickup from moderate to higher speed

If the car feels okay to drive with RPM matching in speed, clutch working fine - you are good to go
Hope should help !!


  1. more than a month ago
  2. Service & Maintenance
  3. # 1
Siva Accepted Answer
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Thanks Admin
  1. more than a month ago
  2. Service & Maintenance
  3. # 2
Rudy Degabriele Accepted Answer
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I have the Hyundai i20 coupe 3dr hatchback 2016 and have exactly the same problem... it happened first 4 weeks a go... i was driving in the afternoon in the heat and my car stopped with the same problem of yours.. gear goes in properly , revs will go up but the car doesn't accelerate. Ps my car has 20,000 km

I went to Hyundai Malta as i bought it brand new from showroom 3 years ago and the car is still under guarantee and told me that the car has a problem with the master cylinder. I waited 2 weeks for the part and told me that my car is ok now and i can pick it up.. today after 2 weeks back with my car the same problem happened again.. car stopped left it for 30 mins then went back and the car became normal again... :( :(
  1. more than a month ago
  2. Service & Maintenance
  3. # 3
Vaman Accepted Answer
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I have an i20 2013 Petrol model driven 18K. Today i am facing the same problem. My car is stationary for last one month so i started the car today plan to reach office by car. My Office is 45 km far from my home. When i am 2km far from my office i realized that my clutch is not normal & when i pressing it, the same cant upward automatically. There were so many car in my behind knocking the horn loudly. I was feel jitter in the jam. Again i started my car & 1st gear up but car is not moving now but after few second its moving, because of the clutch doesn't work properly. After same kind of trouble i reached office safely(damn lately:( ). I am worried what happened to my car so i called to the service centre they told me first they will check & let me know & costing estimation be around 6K.
After 2 hours i was visit my office parking & started my car and gear up, i am surprised my clutch working perfectly.

1.Can anybody tell what is the reason for the trouble this happen for the first time with me????
2. Should i vist to service centre?
3.This Problem has been occur due to stationary of car?
  1. more than a month ago
  2. Service & Maintenance
  3. # 4
Raj Accepted Answer
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I am experiencing the same problem with i20 2013 Petrol model driven only 6K. Was this a common issue/ defect with 2013 i20 Petrol mode?
Issue reoccurs only after you drove for more than 45 mins or more in traffic and hilly areas where you may have to switch gears. Very unreliable since it just stops in traffic


  1. more than a month ago
  2. Service & Maintenance
  3. # 5
Abhijeet Accepted Answer
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Well I brought a used i20 and it had the same problem .
This problem comes when the car stands still for months or you just drive your car ones or twice a month.
The only solution is to change both the clutch cylinders at same time .
It will cost you 950 for lower cylinder and i amnot sure about cost for upper but it is bit costly and break oil is also to be filled.
  1. more than a month ago
  2. Service & Maintenance
  3. # 6
Suresh Kumar Accepted Answer
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I also have an i20 pertrol car and this problem is an existing problem in this vehicle. The other day I took the vehicle after a long time. Initially there was no issue the drive was good. I got a call and I stopped the car to talk (engine was on gear engaged and clutch was pressed). After talking on the phone when I released the clutch the car did not move. I called a local mechanic and he told me what the issue is. The clutch cylinder at the bottom of the engine gets expanded and this makes you clutch hard when pressing. Then he put some water on the cylinder and also some break oil. After about 30 minutes I was able to start my vehicle and return home.
  1. more than a month ago
  2. Service & Maintenance
  3. # 7
Parthasarathy Accepted Answer
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Hello Hyundai Car users : I have an i20 Asta (petrol) which is a 2011 model and I too had the same issue and now having the same issue. I later discovered that this is typical issue on Hyundai cars after discussing with some folks. This is mainly caused due to failure of the Master cylinder and the Slave cylinder in the Clutch actuation assembly. incidentally, I understood that whenever, the car takes a long drive or exposed unused in hot climatic conditions for a long time without use, this problem occurs. Typically, I was given to understand that the cylinder actuation stops or becomes sticky due to heat which causes this issue. This problem vanishes when we switch off our car and let the car engine and the transmission areas cooled for a while (between 10 min to 20 min). If you encounter this issue, you may have to cool the car for a while and keep driving. My advise is, you can probably drive for about 30 min with A/C off, stop when the clutch becomes sticky. The failure mode is like when you apply the clutch, change the gears and try to release the clutch, you will have a strange clutch release feeling where the car never moves either forward (or even reverse). It is better, you drive back slowly to your home or your nearest mechanic and get these cylinders replaced. Incidentally, I too had this experience about 4 years back and observed this after driving about 400 km with 4 people in the car. By practicing this switching off - cool - switch on process, I managed to return home and handed over this to Hyundai. They got these cylinders replaced and the car was perfect. After about 4 years, in hot summer in Chennai, the car is parked in hot sun in my open parking slot and due to Pandemic, the usage of car has become almost nil and hence the problem has started again. I exactly know that the cylinders have failed and i need to get them changed in a day or two. Its a shame on Hyundai to have this design issue and not sure if they have a solution by now. I am not also sure if other car models have a similar issue. I dont also remember the replacement cost - but should be somewhere about 12,000 for the set including labor cost. There is no investigation required to my knowledge or there is a need to suspect the clutch plates. I also recommend that when there is a need for replacing the cylinders, better get them changed as a pair. Good luck !!
  1. more than a month ago
  2. Service & Maintenance
  3. # 8
Quadalert Accepted Answer
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Same issue here with a Hyundai i20 (2015 model). During the Pandemic, we hardly used the car, and after a couple of weeks, when we started using it the clutch pedal got really stiff, We made it to home but couldn't engage gears. Once cooled, the clutch operated normally. The other day we drove and there was a lot of traffic and the clutch pedal got sticky / stiff again.

I called the local Hyundai dealer / parts / service and they told me that the master / slave cylinders have to be replaced. They confirmed that they have this problem with other owners, and they have addressed this issue to the Hyundai HQ, however there's no fix other then replacing the cylinders. I live in a hot summer as well to top it all!
  1. more than a month ago
  2. Service & Maintenance
  3. # 9
Hemant Bakshi Accepted Answer
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Hi All,

I have an i20 Asta Petrol, 2012 model and facing the same issue with the clutch after not using the car much during the pandemic.

I have gone through all the responses above from various members and it seems this is a common issue with Hyundai i20 clutch system due to long periods of inactivity or hill driving and the only solution is to get the Master and Slave cylinders replaced.

Since the pandemic is far from over and the car usage is likely to be minimal in the near future, therefore should I wait for the pandemic to subside completely and normal life to resume before getting the Master and Slave cylinders replaced ?

In other words if I get the Master and Slave cylinders replaced but the car remains stationery for long periods, will this problem reoccur despite the replacement of cylinders ?
  1. more than a month ago
  2. Service & Maintenance
  3. # 10
Pradeep Accepted Answer
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I am facing the same issue with my new I20. It just stopped on the road and clutch got jammed. After waiting for 20 min it started moving, so embarassing on the road. Pathetic
  1. more than a month ago
  2. Service & Maintenance
  3. # 11
Manish Accepted Answer
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I have the same problem. after I drive for about 4 to 5 Kms the clutch becomes spongy and sticks to floor then it returns back to normal position in about 10 seconds or so and becomes very very hard to press, almost as if it was a rock. What I did was put some water and splash it on clutch slave cylinder and within 5 mins the clutch cools down and you can drive next 5 kms before it gets hard again. You need to be a master driver to manage the situation though. Remember don't spill any water on main engine otherwise you will crack the aluminium engine body due to sudden cool water. The entire engine will need to be replaced then.
The solution should be to detect which clutch cylinder is faulty the Master or the Slave. generally it is the slave cylinder. However mechanic Hyundai blindly replace both to loot you!!!
  1. more than a month ago
  2. Service & Maintenance
  3. # 12
Philip Accepted Answer
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I had faced the similar issue with my i20 elite petrol variant bought on 2019 with just 12k kms driven. It's a manufacturing defect from Hyundai it seems. The issue has been persising in the petrol variants of i20 since 2011 and have not fixed yet. I have got my slave cylinders replaced and it seems working now but nobody has guarenteed that the issue will not reoccur again. It looks like a temporary solution and it might reoccur in near future as well. The only thing we can do is to alert our friends relatives and known circle people to not choose petrol variants from Hyundai. It's a great shame on Hyundai for having not fixed this problem over a decade.
  1. more than a month ago
  2. Service & Maintenance
  3. # 13
Chirag Accepted Answer
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This seems to be the common problem with Hyundai petrol variant, I owe a 2016 elite i20 Sportz . This is the Second time I am facing the master cylinder issue . Last year they changed Both the cylinders and yesterday when I went out for a drive My car just stopped in the middle of the road. The clutch stopped working . So I called them and told them the situation . Instead of helping me they were like “ ITS A COMMAN ISSUE WITH ALL THE HYUNDAI PERTOL CARS AND THE ONLY WAY IS TO CHANGE THE CYCLINDERS” i guess even they know about this problem but all they need is to makeup with the losses They faced during the Covid period . It’s a shame to Hyundai . I asked few of my friends with other brands they were like they just some battery draining issues and nothing else .I got this car in 2016 every year I have a exp of Minimum 20k plus maintenance on my i20 . Sometimes i think it was a mistake to buy a Hyundai vehicle .
  1. more than a month ago
  2. Service & Maintenance
  3. # 14
Mukesh Chauhan Accepted Answer
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After reading all Hyundai users comment, after a two years of R&D I have got only one solution that is never buy Hyundai car. Hyundai is not capable enough to resolve his own brand car manufacturing defect. Since 2011 every Hyundai customer those who have Hydraulic clutch in their car has been facing the problem till now and Hyundai has no solution.
Please don't waste your money in changing the cylinders as after a year you will face the same problem. Just sale it out and buy another brand car. This problem is only with Hyundai.
I have done everything change the cylinders/clutch plates and pressure plate also after a year same problem exist.
Forget Hyundai they are just making everyone fool.
  1. more than a month ago
  2. Service & Maintenance
  3. # 15
Muneer Accepted Answer
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I also faced same issue with my 2017 model i20 petrol model. I took the car to my office after the lock down (car not used for more than one month). After around 8 km drive, I started feeling the clutch is not normal and difficult to accelerate after a gear change. After another 2km drive, my car was not at all moving after releasing clutch. Luckly, I had reached the offfice parking area. Car was not moving forward or reverse. I left the car there and walked to my office by thinking I will see the problem in the evening and call a technician. But in the evening, surprisingly my clutch is working normal again. Next day, this problem didn't happen, but happened again 2 times after that. I was very lucky that I reached my office premise in both cases. Now I had given my car to the service centre. Waiting for their call.
  1. more than a month ago
  2. Service & Maintenance
  3. # 16
Arun Accepted Answer
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Exactly the same ordeal which I had to go through. Due to COVID, usage of car was like hardly 30 kms in the last 6 months. and one fine day clutch became super hard and the Master cylinder gave up due to the pressure exerted when got stuck in the main road. changed the master cylinder, still, the same issue persists when the car gets warm. have to wait for it to cool down.

Thanks for this thread that the issue could be identified as some of the FNG wanted to open up the complete clutch assembly to inspect.
Going to the Service center tomorrow to check on this. will let know on their thoughts.
  1. more than a month ago
  2. Service & Maintenance
  3. # 17
RAMAKANT Accepted Answer
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even my experience is same , i am using i20 petrol - sports 2013 / 43000 kms. last year i was on Pune Expressway and car started malfunctioning. i stopped the car at safe place, switched off the engine & spoke to my mechanic friend. He said this is typical problem with Hyundai i20 (one more problem is - breaking of crank shaft pully nut , which is also common) failure of master or slave cylinder. especially if you take car for long drive after long break. fortunately car started & i completed trip of about 1300 kms in 36 hrs. This was on 08 & 09 Oct 2019. problem didn't occur again. i think this is designing mistake & hyundai r&d team should address this issue. approx. cost of replacement of both cylinders - master near clutch pedal & slave in engine compartment - is 12k including labour charges. but most of the time these parts are in minus inventory.
  1. more than a month ago
  2. Service & Maintenance
  3. # 18
Mukesh Accepted Answer
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Have you faced the same problem again after changing both the cylinders?
I had changed the slave cylinder but after 1 year facing the same problem again.

Service center people are saying now to change the master cylinder. But not giving any gurantee that problem will come again or not.
  1. more than a month ago
  2. Service & Maintenance
  3. # 19
Pratik Accepted Answer
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Hi have the same issue. after driving 4-5kms car clutch becomes hard and it stops functioning. i had changed the clutch master and slave in 2018 but now I guess due to COVID as the car was not moving much this problem occurred again. and now even the spare parts are not available due to large demand of this faulty issue in cars
  1. more than a month ago
  2. Service & Maintenance
  3. # 20
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