Clutch problems post starter motor change (Sorted!)

[spannermonkey]

Hi All,

Ok, I now have some problems changing gear, almost certainly caused after changing the Starter motor on my 1.6TD Syncro.

To remove the old starter and refit the new one involved undoing the forward part of the clutch slave cylinder bracket and then rotating the bracket downwards/anti-clockwise (starter motor flange sits between slave cylinder bracket and bellhousing).

In doing so, the actuator was compressed against the clutch lever. the thing is, on now driving, the gear change has drasically worsened. It's not totally undrivable, but gear selection (in andout)is very reluctant and makes for interesting moments on the road when you can't get into gear!. The following is also of note; 'bite' point has dropped to the very bottom of pedal travel and there is slightly less pressure on the pedal, no leaks are apparrent on and around the slave cylinder and fluid level is at maximum in the reservoir.

I've looked at the bentley manual, but not too sure where to start in rectifying this problem. Any ideas on what the problem might be and how to proceed?

Cheers,

Steph

[Aidan]

Steph
you do have a support strut for the slave bracket don't you ?

[spannermonkey]

Yes, I think so; the one that points down at about 45 degrees and towards the front, that's the one I loosened off in order to rotate the slave bracket downwards.

Had another look over today and still no obvious leaks and the reservoir level hasn't budged that I can see. Wondering if I have caused any damage to the slave somehow.

Another point of note is that my set up looks slightly different to the syncro setup in the bentley, with the connection to the slave and rigid pipework heading towards the back of the van and then curving underneath the slave bracket before joining the rubber flexi, rather than heading forwards as per Bentley pic.

[spannermonkey]

Ok, problem solved!

First plan of attack was to bleed the clutch and see if that made any difference. Things improved a little, pedal feel much better, but still the reluctance to change gear.

Decided to bite the bullet and replace the slave cylinder and bingo! When I did a side by side new and old, it was apparrent that there was a problem with the old slave:- the piston was not making it's full length of travel - I think where the boot had failed and gunk had entered, this was hindering full movement. I just obviously made things worse when I had to rotate the slave bracket and move the actuator about.

Van now changes gear as it should - result!