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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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