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Subject:Re: Clutch slave cyl. replacement: What could go wrong? Well.....Friday sort of.
From:SDF ( aka ;jim lahey' - Scott )
Date:Fri, 5 Sep 2014 11:29:01 -1000

re 'rear mounting bolt' on the clutch slave ..
it's very easy to convert that bolt to a stud...which makes it really
easy to undo that one spot.

unless one is a really fantastic welder...
either the bracket or the whole trans needs to be out of the van ..
then it's easy to arc weld a bolt into the bracket , which makes it a stud.

if bracket is in hand ...not neccessary,  but it's useful to add some
reinforcement in the form of a gusset.

Beware of cases where people have left the forward support bracket off.
Leaving that part  off can eventually lead to a cracked slave bracket
and lost motion.

On 9/5/2014 11:16 AM, Don Hanson wrote:
>    I'm pretty sure my clutch slave cylinder failed yesterday.   No clutch
> action, bled it and drove some but this A.M.,  I checked in theslave's
> rubber  boot and it was full of hydraulic fluid. The  brake fluid reservoir
> would not hold pressure very long from my Motive pressure bleeder
> either.....
>
>     "No problemo" says I..."I have a spare under my seat"   I've done these
> before and while it is a nasty messy job and frustrating with the rear
> mounting bolt, it isn't rocket surgery....
>
>     So first I have to fix one of my jacks tands, it's been semi-broken for
> some time...the pawl would release, but only with fiddling.   I find the
> roll pin is broken connecting the shaft of the pawl and the lever to
> release it.   OK,  so I do that.
>
>     Dig into my brake bleeding box and find my bleed hose...It's turned to
> gum and is no longer serviceable..  It feels like an eraser now, not
> resilient at all, won't stay on the bleed screw.   OK, fix that.
>
>     I decide I should inspect for leaks in the whole brake/clutch system.  I
> fill my Motive pressure bleeder bottle and screw it onto the brake
> reservoir above the steering wheel, then pump it up to about 20psi and
> crawl under to look for leaks..   After about 3 minutes rolling around on
> my creeper I find no leaking but.....I hear a "Phut...psssssssssss,
> ker-thump!"   "Uh-Oh!"   I roll out and find the hose between the pressure
> bleeder and the brake res. has popped.....and there is brake fluid sprayed
> from end to end....inside the van...All over everything.   Including my
> very pricey bike, some sailboards, clothes, upholstery, pillows,
> headliner...it even got to the rear hatch window!  What a mess!  So a
> couple of hours trying to clean the brake fluid off every-frikken thing...
>
>     Next, I decide "OK, no leaks...I'll just put on the new slave and bleed
> it with my mighty vac and be done"   but of course, the Mighty vac (or
> whatever harbor freight calls theirs) also has rotten gummy hoses that need
> fixed. Then it sucks fluid into the 'squeeze pump' rather than into the
> cannister that it's supposed to go into...So I have brake fluid running up
> my arm into my pit....as I try to bleed the air out of the slave....Now I
> am a REAL mess, the shop floor is puddled and the inside of the van is
> trashed.  Hopefully I got all the brake fluid off my Colnago, which is
> worth more than my van..
>
>     So next,  I take my spare Blue Hose hydraulic line and put that onto my
> Motive Pressure bleeder to fix THAT,  and finally.....finally....bleed the
> slave without anything blowing up or leaking all over everything...Oh,
> wait....when I go to remove the excess fluid from the reservoir, the horse
> syringe I use....the plunger comes all the way out and I dump brake fluid
> on the floor of the van...no worries.... as it's already saturated from my
> recent blow out of the pressure bleeder...
>
>     Sheesh!  What could go wrong on such a simple task?....those are some of
> the things that did go wrong....
>
>     (at least it isn't a windy day and I am not missing out on windsurfing
> time to take a brake fluid bath....Ha!)
>    Don Hanson
>