Date:         Sun, 15 Oct 2006 17:21:10 -0700
Reply-To:     Barrett Willet <barrettw@NVENTURE.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Barrett Willet <barrettw@NVENTURE.COM>
Subject:      Re: Clutch Hydraulics Problem
Comments: cc: Keith Ovregaard <kovregaard@COMCAST.NET>
In-Reply-To:  <ab64e32c74db918001f2b23545a880d2@comcast.net>
Content-Type: text/plain; charset=US-ASCII; delsp=yes; format=flowed

This could be a case of a worn clutch pedal and clevis.  The clevis
attaches to the clutch pedal with a pin without any kind of bushing
or bearing.  These are prone to wearing out over time and it exhibits
the same behavior your describing.  Has your clutch pedal ever stuck
in place when depressed and requires a little tap with your foot to
spring back in place?
I had this same problem on my '88 and focused entirely on the
hydralics with no success.  You might be able to reach up above your
master cylinder and see if there is much play up and down in the
plunger shaft.  If it wobbles around you have found your problem.
The repair is a bear but creates some opportunities for preventive
maintenance.  To access the pedal cluster you have to drop the
steering column and remove the dash.  Even then things are still
pretty confined.  While the dash is off it's nice to check condition
of front heater core, clean the main fuse box grounds and perform any
rewiring.
To repair you can order another clutch pedal and clevis from the
dealer but when I did mine about a year ago there were only 12 pedals
available in the US.  I chose to weld the hole closed and redrill an
oversized hole so I could put in an Oil-Lite bronze bushing.  Let me
know if you would like to see some pics of the worn parts.
Unfortunately I never took any pictures of the repaired pedal with
bushing.
Good Luck
Barrett
'88 Wolfsburg

On Oct 15, 2006, at 4:35 PM, Keith Ovregaard wrote:

> Hi all,
>
> Just wondered if any of you have experienced this situation and what
> the fix was:
>
> Clutch engages when pedal is very close to floor. I thought there was
> air in the lines, but no change after all clutch and brake lines bled
> with pressure bleeder. No leaks at master or slave. Bled second time,
> no change. Bled again the old fashioned way with slow push on the
> pedal
> with the bleeder screw open using a bleeder kit from FLAPS. Still no
> change.
>
> So, are we talking internal seal leakage? Replace both slave & master?
>
> Thanks in advance for any help!
>
> Keith O.
> 90 Westy Syncro "VikingWagen"