From cable to hydraulic clutch.

[zxr750]

Hello,
I'm converting from cable to hydraulic clutch.
The van is a 81 A/C, RHD, the pedal box came out of a 86 1.9 petrol, RHD.
there's a hard white pipe coming from the master cylinder, where does this pipe exit the foot well?
I've tried routing it through the existing hole for the cable but it's kinking the pipe.
The van has had some welding done around the hole so that might be causing the problem, unless it exits elsewhere.
Any help/pics will be appreciated.
Thanks.

[zxr750]

OK,
where does the pipe run from inside to outside on the hydraulic set up?

[ermie571]

I'm not entirly sure its as easy as you may think...have you got all the hydaulics for the gear box end too?

I have no idea when the pipework goes....have you got a haynes manual??
rand you will have to break into the the brake hydraulics as they share the cylinder up front. the clutch feed comes off above the brakes, so in the event of fluid loss, the clutch goes before the brakes...

But do check that your gearbox will accept a cylinder down there too - there is a horrible bracket that the cylinder mounts on..its a bugger to get to if the cylinder ever needs changing....

Good luck!

Em
x

[zxr750]

Hello Em,
Thanks for the reply.
Yes I'm swapping the complete gear box for one with hydraulic clutch, and the clutch master cylinder is at the bottom on this pedal box.
The only hole I can see for it, is the one the cable came through but it kinking the pipe when I've tried it through there.
The holes for the brake pipes line up the same so no problems there.
Thanks.

[The Bobdogs]

Bit late to the party on this one...but just in case it helps anyone else....
Change the bellhousing and keep the cable clutch....soo much easier and the cable clutch is more than up to the job and not heavy on the foot either.

[billy739]

super late reply , yes it goes through the cable hole in the floor.

early pipes are metal , late are plastic to a join just outside (tight against the rad on watercooled)

[zxr750]

Thank's for that billy.
Yes very tight against the coolant pipes.
The van was originally a 1.6 CT, then converted to 2.0 CU.
The gear box code is DK but it's cable clutch, others I've seen are hydraulic, were they made with both?
I'm hoping to use the conduit that the cable ran through, for the copper pipe.
It's now the flexy (slave cylinder) end I'm struggling with.
Any pic would be appreciated.

[Smiffo]

Thank's for that billy.
Yes very tight against the coolant pipes.
The van was originally a 1.6 CT, then converted to 2.0 CU.
The gear box code is DK but it's cable clutch, others I've seen are hydraulic, were they made with both?
I'm hoping to use the conduit that the cable ran through, for the copper pipe.
It's now the flexy (slave cylinder) end I'm struggling with.
Any pic would be appreciated.

Give me an hour mate and I will be out with mine then - Can you post a pic of what you have and where you need our photos taken?
I will then replicate the angles with my van and post pics here.

[zxr750]

Top man smiffo,
I could do with a pic of the flex pipe bracket, to see where it's located.
Thanks again for your help.

[Smiffo]

Top man smiffo,
I could do with a pic of the flex pipe bracket, to see where it's located.
Thanks again for your help.

Do you mean the bracket that the slave cylinder bolts to, or do you need pics of the route the flexi pipe takes?
Mine doesn't seem to have a specific bracket for the flexi pipe, it attaches to slave cylinder one end, then is free to the bit where it attaches to the metal pipe going to the front of the van...

I will upload a vid if needed.

E D I T - here are two vids below of the route the flexi pipe takes:

https://www.youtube.com/watch?v=yrl5kX_-iYc" onclick="window.open(this.href);return false;

https://www.youtube.com/watch?v=67wMn_JV-_U" onclick="window.open(this.href);return false;

and then one more of the bracket that the slave cylinder attaches to - it probably won't help much more than the first two though?:

https://www.youtube.com/watch?v=aWdb8jjqe1k" onclick="window.open(this.href);return false;

I was just going to post pics, but they came out c***...

[zxr750]

Excellent, thanks for that pal.
Unfortunately I have the rubber flex hose, which I think goes into a bracket through a round hole and held in place with a fork type clip.
Very much appreciated the trouble you've gone to though mate.

PS
Excellent camera work there smiffo.

[Smiffo]

Excellent, thanks for that pal.
Unfortunately I have the rubber flex hose, which I think goes into a bracket through a round hole and held in place with a fork type clip.
Very much appreciated the trouble you've gone to though mate.

PS
Excellent camera work there smiffo.

It was no trouble at all.
It gave me 20mins rest-bite from cursing and swearing at the linkage I was mincing around with all afternoon..!!

Hopefully someone else will be able to post something similar on their setup, that might reflect what you have....

[billy739]

the flexi rubber hose and metal pipe combo is the early set up. vw went to 1 piece plastic pipe thereafter,

you should fit a plastic pipe , simpler in the long run , no support bracket

brickwerks should do new , I will have a used one.


2.0 only came with hydraulic , the bell housings are swapped to keep it simple. it seems with the 228 clutch vw thought hydraulic was better.

[billy739]

google search , found this

http://www.bing.com/images/search?q=+ai ... ajaxhist=0" onclick="window.open(this.href);return false;