Date:         Sun, 8 Mar 1998 19:23:34 +0000
Reply-To:     Harry Yates <hyates@BERT.CR.BCIT.BC.CA>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
Comments:     Authenticated sender is <cr\hyates@bert.cr.bcit.bc.ca>
From:         Harry Yates <hyates@BERT.CR.BCIT.BC.CA>
Subject:      brakes/clutch bleeding - success!
Comments: To: vanagon@vanagon.com

Hi Folks.  Well, I did it!  As per the many suggestions I had from
this list, and especially Tim Smith, I was able to flush these lines
out with no problem using the two people method.

Bleeding the brakes on the van is the same as any car, and my fluid
was in the van for two years.  It was a bit murky, but not too bad at
all.  I ran into a bit of a problem at the LR wheel cylinder as the
fluid wouldn't come out of the bleeder nipple.. it came out the
threads!  So, I had to remove the bleeder screw, and clean out the
bleed hole at the base of the screw.  What a mess that made with
brake fluid running down the backing plate.  A bit of a clean up job
there.  Anyway, got the brakes done  using 3 jugs of fluid (12
ounce or 355 ml).

When bleeding the clutch, it was really straight forward, and easy.
Pumped about 3 times, and then on the beginning of the forth stroke,
I opened the bleeder, and closed off before my buddy's foot hit the
floor with the pedal.  This was easy, but a bit slower to do than the
brakes.  Basically, I pumped an extra jug of fluid through to clean
out the clutch line.  Now, that clutch line was disgusting!  The
fluid was black.  I couldn't believe it!

My van has had the brake system flushed every two years since it was
new in 1990, and looking at the fluid coming out of the clutch slave
cylinder, it would appear that it had never been changed.  I just
checked my records, and the dealer had charged me 0.85 hours of
labour to do the brakes, and used 2 - 12 ounce jugs to flush out the
brakes.  So, it is obvious to me that this isn't enough to completely
flush out a Vanagon brake system.

So, this cost me 4 - 12 ounce jugs of Super Dot 4 fluid ( I used VW's
stuff ), and it took us about 3 hours to do.  Hey, I didn't say I was
fast!  But, I sure advise to flush out the clutch circuit.  You don't
even have to go under the van for that, so it's really easy and
convenient to do.

Hope this helps someone out.
Harry.
---------------------------------------------------------
Harry Yates, Langley, BC, Canada
'90 Syncro Westfalia www:   http://syncro.bcit.bc.ca/hyates
'87 Golf Diesel      email: hyates@bert.cr.bcit.bc.ca
'91 Miata (Millie)