On Thu, Jul 1, 2010 at 8:28 PM, Scott Daniel  - Turbovans
<scottdaniel@turbovans.com> wrote:

> my thoughts are that it's not likely to be the clutch master cylinder
> itself...
> but the clutch pedal and the clevis pin ..
> something to do with the pushrod etc.
>
> I have never done it , but I have read that it's possible to cut an access
> hole in the front of the van behind the left headlight to get easy access to
> that mechanism.

.....

> if there is some extra free-play on top of the pedal travel.....try
> adjusting some out,
> and even that is a pain of course.
> and you spray lubed up in there as best you can ?

> I always lube the ends of pushrod that go against hydraulic cylinder pistons
> ..like at the clutch MC and the slave too. ...
> never have seen that mentioned anywhere, but I think *any* metal-to-metal
> dry contact is a very bad thing.

> if you lubed the upper end of the push rod decently with a good grease. ...
> my vote goes toward the clevis pin and hole....and clevis itself. �I always
> thought they were just loose and funky anyway. like a much more cheaply
> produced part than the entire rest of vanagons, which are really well made
> vehicles overall. �Unusually so even.
>
> it's the single hardest adjustment anywhere in a vanagon . - clutch master
> cylinder push rod length adjustment. �And it's trial and error too , adjust,
> put together, see what �ya got, etc. A real bother sometimes. .

Hey Scott.

When I installed the new clutch MC, due to newb ignorance, I never
adjusted the cylinder push rod. It worked fine so....

And grease at pushrod end where it meets MC piston? Had wondered today
if I should have done that at time of install. For sure! Great idea.
If I pull the cluster out, I'll do that. And of course lube the clevis
etc. It was a while back, but IIRC, I hadn't lubed anything beyond the
bushings at time of assembly. Bad move. D-oh!

The click sure feels like something that "settles in" to place once
enough pressure is exerted on it. Yah. I bet the clevis hole repair I
did failed OR the clevis pin is worn and settling into place. Can't
feel anything rubbing up there.

Now that I have a MIG, I bet I can do a better job of it. ... or just
replace the pedal with the good one from the '85 (thanks again for
prompting me to pull as many parts as possible off of that parts van a
coupled years ago). That pedal cluster looks nice.

I had read of the access hole in the archives. Seems maybe overkill
somehow, but makes sense. Such a PITA thing to get to.

Neil.

-- 
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines