Clutch problems!

[SpongebobSquarebus]

Our clutch failed suddenly on our 83 air-cooled camper. The pedal went straight to the floor at a junction so couldn't select any gears . Checked the clutch fluid level and it was down past the minimum level, the pedal is pumping themaster cylinder but the slave cylinder doesn't operate.tracing along the hydraulic pipe I found what seems to be clutch fluid ( its clear and doesnt smell of petrol) over the front and back edges of the fuel tank so I'm assuming the pipe has burst above the fuel tank . Do I need to drop the fuel tank to replace the pipe or can it be rerouted or could I be wrong with my diagnosis? would the pipe fail that instantly?
Any feedback would be much appreciated

[weldore]

your very old steel clutch pipe will have corroded and its leaking.its possible to feed a new lenght of copperpipe over the tank but you need to renew it all the way

[weldore]

oh and yes..its instant

[SpongebobSquarebus]

Ok thanks for confirming my fears, do you know if the pipe is something I can buy easily or will I have to get one made up?

[weldore]

i did mine the first week i got my van as it 'went' on the way home from buying it .
now dont quote me on this as i have a memory like a fish..
under the spare wheel is a joint you can go off and it will run all the way to the slave cylinder on the gearbox.
youwill need the correct unions for both ends of the pipe and 'i think' i used normal brake pipe from any motorfactors(anyone correct me on this ?).BUT you will need to hire or buy the tool to make the ends up on the pipe.

it might be worth taking it to a garage than to buy the flaring tool..but while your under there having a look...see what your brake pipes are like...if they are shot too then it would be a lot more cost effective to buy the kit
on ebay they go for around 50 quid with loads of pipe and some unions..and replace the lot

thats if your handy with stuff like that or willing to have a go

oh..itll be no good trying to let a section in to the existing pipe as it wont allow you to flare it properly..as itll be brittle

[SpongebobSquarebus]

Thanks for the help, I think I know someone who can make up the pipe for me then I can fit it myself, there's not much left that hasn't been replaced on the van so hopefully we might get some reliability now It's certainly a learning curve owning these but you do get to know them inside out!

[weldore]

undo it all and take it out so you know how long you need the new one..id make it another foot longer actually...when you feed the pipe through over the fuel tank tape it up with the union on the end so you dont scrape crud into the end of it

oh..and check the unions will feed through the holes in the bodywork as i cant remember if they did

[SpongebobSquarebus]

I got to work on removing the pipe this evening and have removed both ends. Had to cut the pipe either side of th fuel tank as it won't come out due to it already being repaired with flexy hose with big jubilee clips holding it on so it won't pull through (the pipe has a2inch split in it hence the instant fail of the clutch!) going to run a continuos pipe right through to the slave cylinder as suggested ( can't see the need for the need for the joins between solid hose to flexy and back to solid near the slave cylinder?). Is there any reason why it should be routed over the fuel tank? It can be routed a lot more direct route with less bends which I think would be fine as long as it secured well?

[weldore]

see what you can do for best but i did manage to get mine over the tank...praps if you got some stiff wire or maybe a length of net curtain wire and had a go..then pull it through with the pipe taped to it.

flexi-pipe..on a hydraulic line..held on with jubillee clips...crazy !!

if you have to go to the master cylinder then you need to put a really sharp bend in the pipe..have a look at the old pipe near the pedals

[SpongebobSquarebus]

Sorry meant slave cylinder Going to connect where you suggested on the joint under the spare wheel

[weldore]

oh..you are going to connect to the flexi on the slave arnt you..movement might be an issue if you dont

or is it buggered ?

[SpongebobSquarebus]

The hose looks ok, I'll leave in place if it's a safer option, didn't think about the movement around there but does make good sense

[weldore]

good luck..im sure you dont need it

[SpongebobSquarebus]

All done and working great, did have a he'll of a scare though when I drove it off the drive and turned it around, looked underneath and there was fluid dripping everywhere ! Turned out to be all the spilt fluid on top of the fuel tank running off, phew!