Date:         Sun, 10 Jun 2007 18:05:57 +0200
Reply-To:     Jens Jakob Andersen <jayjay@ZORCK.DK>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jens Jakob Andersen <jayjay@ZORCK.DK>
Subject:      Re: Clutch problem - input needed - Now solved
In-Reply-To:  <BAY125-DAV834251634B9E33DA00A9FA01B0@phx.gbl>
Content-Type: text/plain; charset="us-ascii"; format=flowed

Dear Vanagon list

THANK you all for your support in my mysterious clutch problem.

Now solved.

Answer?

1. The reason that the clutchpedal couldnt travel more than halfway
to the floor: Slavecylinder was at max travel.
2. Why? Dont know, really dont know. Guess that worn fingers on the
releaseshaft is the answer.

3. I got a spare slave yesterday evening, late, 2330 at Caspers - by
way of http://www.t3nettet.dk

4. Spare didnt work, bleed-screw was sorusty that it broke when I
tried to release it.
But good to have it, and study it. Interesting to see inside the
spare-slave, that due to rust, the piston couldnt travel all the way down.

5. Used it to measure piston travel, and found out that my slave
maxed out. Removed the rubber from my slave, and saw visually that it
was maxed out.

6.Poked around, pulled my slave, found that the pushrod of the dead
spare slave was LONGER (5 mm) than the pushrod in my slave.!!!

7. Worked around, switched pushrods, did also lower the
slavecylindermountingbracket a bit by undoing the big bolt holding it
to the engine case, and placing a thick spacer between bracket and
engineblock, thus rotating bracket a bit, and making it move a bit
closer to the releasearm.

8. So - my best advice if anyone else have this problem - visually
inspect the travel of the slave, and if maxed out - see if a longer
pushrod can be found

http://www.t3nettet.dk/album_pic.php?pic_id=578

Happy driVWing

Jens Jakob, Denmark