Date:         Thu, 12 Dec 2002 09:16:10 EST
Reply-To:     THX0001@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         George Goff <THX0001@AOL.COM>
Subject:      Re: Thnings that go "Squish" in the night
Comments: To: j_rodgers@CHARTER.NET
Content-Type: text/plain; charset="US-ASCII"

In a message dated 12/11/02 6:45:47 PM, j_rodgers@CHARTER.NET writes:

<< Anyone got ideas as to what this "Squish" is about? And if it's clutch
master cylinder - how hard to replace? >>

John,

I have no way of knowing for certain, but it sounds like the clutch master
cylinder has seen better days and leaking into its boot.  Since the clutch
and brake master cylinders draw from a common reservoir, some of the crud
which fouled your brake cylinder might have migrated to the clutch cylinder.
It certainly would have been easier to replace both at one time.  Removing
the clutch cylinder is the typically nuisance ridden Vanagon job.  Some
things I do are:
1) Suck out as much of the brake fluid from the reservoir as possible.  A
large syringe is nice for this, but an empty squeeze bottle will work.
2) Fill the reservoir with fresh fluid and flush the system thoroughly
through the slave cylinder bleed nipple before removing the old cylinder.
3) Repeat Step 1).
4) There will still be some fluid in the make up hose so have some rags ready.
3) Installing the new cylinder, I find it is best to run the flare nut in by
hand until it bottoms before I install the cylinder mounting bolts.  This
way, the slight movement needed to align the hydraulic line to the cylinder
is possible.
4) Here is the biggest nuisance.  There is supposed to be freeplay between
the piston and the actuating rod, which makes sense.  It is supposed to be
.020", which doesn't make sense.  And, if there is a mortal man who can
adjust that clevis on the end of the actuating rod with it in place, I want
to meet him.  If adjustment is needed, I take the actuating rod out to do it.
 I also disconnect the clutch return spring so that I can work the clutch
pedal by hand to feel the freeplay.
5) I use a pressure bleeder of my own devise to bleed the system.  The first
time I did one, I did not use a pressure bleeder and I recall that it took a
bit of screwing around to do it that way.

George