Date: Sun, 8 Feb 2004 16:25:03 -0800
Reply-To: Joel Cort <joel_cort@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Joel Cort <joel_cort@YAHOO.COM>
Subject: Instructions for replacing the Clutch Master Cylinder
In-Reply-To: <BC4C02A4.AF93%tornadored@earthlink.net>
Content-Type: text/plain; charset=us-ascii
James,
I found this write up I had put together a while back, on instructions to do this job.
This is a fairly easy job to do. It could get real messy if youallow the brake fluid to drain all over the floor board andcarpeting.To prevent that, what I did first was drain enough fluid from thereservoir on the brake master cylinder to go below the clutch mastercylinder line level. - I syphoned it out but there are other ways.You can put a drain hose on the bleeder valve and open it drainingall you can. You can also open the bleeder back on the slavecylinder and drain the entire system. At this point pickup the John Muir book and read the part aboutgetting in the back of the van with your loved one and relax. Ok with most of the fluid sufficiently drained, loosen the line-outpipe to the slave cylinder. Place rags underneath and let it drainoff any fluid. Place a container underneath to capture all the fluidthat you can.Have lots of rags handy under the brake pedal. Don't get any fluid onany paint it will eat it up. If you do spill use rubbing alcohol toclean it up quickly. I
guess you better not be reading the Muir bookand smoking a dubby while doing this. It might scorch your van.Ok back to the master cylinder: Ok disconnect the fluid line-out tothe slave cylinder. Note the two copper washers there is one on theoutside and one on the inside of the hose connection.Loosen the two bolts that hold the master cylinder in place on thebracket. Now you can pull out the master cylinder and hold it inyour hands. At this time you can wiggle the main fluid hose comingfrom the brake reservoir and work it off the unit.Clean up the area and you are ready to replace with the new one.Insert the brake fluid hose from the reservoir back on. You may usesome silicone to get it on snug. No clamps required. If it is wornedand cracked you may want to replace it as well.Check that the plunger pin is well situated in the pedal mechanismrebolt the clutch master cylinder in position.rebolt the line out to the slave with one copper washer on each sideof the bolt. You may need
to replace those washers.And now you are ready to add new fluid and bleed the system.Here is the trick. The slave cylinder is lower than the clutchmaster so all you have to do to drain the air out of the line is toopen the bleeder on the slave, add plenty of fluid in the reservoirand wait.Let Gravity work for you. To quote john muir some more,relax and warm up with a friend.Ok ok, you can help it along by pumping the clutch pedal. repeatuntil you feel pressure and the slave is moving the throw-outbearing.I found out that it took about a week of driving to get the pedaladjusted automatically with the proper amount of free play so don'tgo trying to adjust the plunger or anything give it some time and itshould adjust to the proper freeplay. If you can engage the gearsand change them with little pedal play, that's OK it will adjust intime.Another thing that happens about 6 months later or before this is thepartner slave or the master goes out too. So might as well changeboth at the
same time and save the rest of the afternoon.Good luckJoel89 Syncro Westy MVRochester NY.
James V <tornadored@EARTHLINK.NET> wrote:
I've got a leak coming from my clutch master cylinder on my 90 Carat.
(fortunately not the brake m/c).
It appears to be coming from the top, as the "piston" and boot are soaked in
fluid. The rubber accordion boot is connected at the top to the piston but
is loose at the bottom and exposes the piston when the pedal is depressed
(I'm guessing this should be connected, but is probably unrelated to the
actual leak?).
So, assuming the m/c needs replacement, how difficult of a job is this for a
novice mechanic? (I haven't done much more than routine tune-up stuff). My
shop quoted around $250, but it looks like the part is only $50 from Bus
Depot (anything additional parts required besides brake fluid?).
Advice appreciated.
James
90 Carat
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