Date:         Thu, 26 Aug 2004 13:13:58 +1000
Reply-To:     Stephen Overmyer <S.OVERMYER@UWS.EDU.AU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Stephen Overmyer <S.OVERMYER@UWS.EDU.AU>
Subject:      Replacment of the clutch master cylinder
Content-Type: text/plain; charset="US-ASCII"

 
Hi Everyone,

I recently had a big day as the Wasserboxer was due for a minor service
at 263,000kms and also I had to investigate a
hydraulic fluid leak appearing as a few small drips on the floor below
the clutch and brake pedals.
Turned out to be a leaking clutch master cylinder.....no big deal, just
a bastard to get to...:)

I also felt it was time to repack the CVs as I've never touched them in
the whole 263,000kms and I could feel a slight vibration under
acceleration that felt like CVs....Well it was only when I removed the
CVs and cleaned & inspected them, I realized repacking wasn't going to
fix the wear spots in the casings thru the hardened surface...so the day
just got a bit bigger with 4 Cvs to replace, not to mention the mess of
playing with CV grease.

I also thought it was time for a good look at the front disc pads since
they have only been replaced once, along with the rotors at around
125,000kms. Pads were worn, not completely gone but hey, since I'm there
I may as well do them too.
What the hell it's only money right? Rotors are still fine, only the
slightest of lips on the outer surface so they should be good for the
foreseeable future...I filed the edges off the new brake pads to avoid
the lip and in they went.

Now everything is fine and dandy...not bad for about 5 hours work incl
bleeding the hydraulic system...the clutch and brakes feel good , no CV
vibration and another routine service out of the way.
First replacement of the clutch MS in 12 years & 263,000kms, first look
at the CVs in the same time and distance and only now at 263,000kms, the
van is on it's third set of front pads. The rears, shoes and drums were
replaced at around 150,00kms and the second set are still going fine.

So much for Volkswagen (alleged lack of )reliability eh ? ;) 

Anyway having said that, I may have a little problem but if so, I'm
blaming pilot error ;)

The clutch master cylinder's manifestation of drips onto the rubber
floor was I found, after it had been slowly leaking down under the floor
mat onto the metal floor under the driver's feet for I assume the past
few weeks. No obvious drop in the reservoir and no apparent problem with
the clutch either for that matter...

I cleaned up all the leaked fluid however, after driving the van a few
days during the past week, I keep finding a little fluid residue back on
the floor under the rubber mats on the flat part of the floor. Oh
bugger, I still have a MS leak was my first thought but there is no
apparent leak at the MS, none on the floor directly under the pedals,
nor has the fluid reservoir level fallen.

Is it possible that the rubber floor mats have absorbed some of the
leaked hydraulic fluid and the heat from the coolant pipes warming the
floor has caused it to sweat back out onto the floor?

I really don't *think* I still have a leak but I'm not fully dismissing
it either however I'd prefer to go with the rubber sweating theory if I
can...;)

Is this feasible...or am I more likely in denial? ;)

Thanks,
Steve O
NSW Australia
'92 Transporter WBX Kombi
'00 Transporter Double Cab
'03 Transporter Double Cab (work truck)
'78 Landrover Series 3 Soft top (ex-Aust.Army)