Date: Fri, 17 Mar 2006 12:31:58 -0500
Reply-To: Roger Sisler <rogersisler2000@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Roger Sisler <rogersisler2000@YAHOO.COM>
Subject: Re: Frozen slave cylinder
Hello Jim. I did this repair last week. It was the second time for me. From
the first adventure ,I learned the correct way to do this. Itshould only
take 30 minutes.Not the two hours the first time took.
First,have the new cylinder ready for installiation(place it within arms
reach of the cylinder mount,where the old cylinder now is. Next, loosen up
on the 12mm hydraulic line and turn out the flare nut,till it can be
removed by fingers only.Use a flare nut wrench,if possiable.Next, loosen
the two13mm bolts that hold the cylinder to its mount. Remove the flare
nut, and letthe brake fluid drain intothepan under thevan.Next, remove the
mounting bolt that is closest tothe steering wheel. Placehis , and itsnut
within arms reach ,on theengine deck. Now, here is the way to save your
time and frustration. Place your index finger on the head of the last
mounting bolt ,and remove thenut. While still holding the bolt in
place,remove and toss the old cylinder over your shoulder(dont take the
time to look at it right now !)Grab the new cylinder and stick the pushrod
through the mount hole, and into the proper position(stillholding the last
bolt head).The mounting holes will now line up and the bolt that you have
been holding will go right through. Put the nut on ,quickly.Whew! Put the
remaining mounting bolt in place and hook upthe hydraulic line. Be sure to
fill the resivour to the top before you remove the line from the
cylinder.Now run toteh resivour and top it off again. Tighten up on the two
mounting bolts and hydraulic flare nut.Top theresivour off again. Recheck
the three connections you just made,for tightness. Now , you can look at
that old junk cylinder allyouwant.
Place a hose on the bleeder valve and place the other end into a bottle of
fluid that covers theend of thehose.Loosen teh valve and pump the clutch
pedal slowly several times. Check thebottle andsee that dirty fluid is now
mixing with the clean fluid. If allis ok, continue to pump the entire 1
pint of brake fluid through the lines. Dont let the resivour go dry. Topit
off every 8 or 10 pumps.Tighten the bleeder swrew ,and you are done.30
minutes to 1 hour total.Should work fine now.Thisrepair can be done from
the topofthe engine compartment.Go clean yourtools and wash yourhands.
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