synchromesh hard shifting and gear linkage

[mrdp]

Hi , I'm Not sure from memory on the sizes and I used a hose clamp on the flexi tube to stop too much fluid escaping, but then I had a replacement slave cylinder ready to put back on fairly quickly..I think your problem will be either the slave or master cylinders or could even be both I suppose. The slave is fairly straight forward. and I would have thought more prone to failure based on its location ie under the van getting covered in crap as opposed to under the dash board nice and dry !! There is a page on Wiki to describe the process if you don't have a haynes manual . The only thing I was unsure about was they said to jack up and remove the rhs rear wheel I got to mine from the LHS rear wheel but probably best too get under the van and have a quick look first.

[xpress]

here are some pictures, one is of the clutch slave with the pedal up, and one with the pedal down.

and there's a video on there too.

http://s1059.photobucket.com/albums/t43 ... t25clutch/

can anyone see from there if it's not travelling fully?

it looks like the union can come away from the flexi tube, there's a doubled domed end on the union going into the clutch slave that looks like what you get on a petrol petcock, you can bet your life that pipe might be brittle and stuck to that union though.

i tried turning the 11mm union going into the clutch slave cylinder with a brake pipe spanner, and it wouldn't budge, is it ok to heat the surrounding outer circumference area of the cylinder union opening here with gaslamp, as far as anyone knows is it away from any petrol lines?

i tried the nut head underneath that holds on the clutch slave, it is hard to turn and kept on turning, do you have to hold it at the top of this screw while turning below? there only seems to be one nut and bolt holding this on.

[mrdp]

Hi there should be 2 bolts holding the slave on .you may need to get to the second bolt from the engine bay and the other one from underneath the van. The union should stay on the flexi tube and unscrew from cylinder .the pictures you posted clearly show the arm moving but mine also moved' just not far enough. Its hard to say if yours is moving enough. Is there any fluid loss when you squeeze the rubber boot?

[xpress]

hi mrdp, i did see some wetness on the boot, i wiped it all off but it didn't smell of brake fluid, will see if it reappears. i will squeeze the boot and see what happens, it was very hard to get the union free, i think it will need some concentrated heat and quenching with some releasing fluid. one of the perks of an old van. are the two nuts side by side or is there one hex head above and below on the same thread? you're right, the clutch slave may not be travelling far enough. i have to get this slave off so i can open it and have a look in the bore, i did the same with the front calipers and they needed a clean and just before i put them back on so i do know what you mean about a lip causing things to stick. definitely worth stripping off and checking..

[xpress]

are there any kits to replace the seals for the slave cylinder?

[mrdp]

Probably best to just buy a new one gsf sell them for 30 odd pounds ...

[xpress]

right, it's order new one, then operation get this thing off, which will probably take some coaxing, then i will keep you posted! many thanks.....

[AdrianC]

Probably best to just buy a new one gsf sell them for 30 odd pounds ...

GSF might sell 'em for thirty-odd, but a look at BW shows two - just under £40 or a tenner more. I think I'd be springing that little extra for a quality difference.

[Aidan]

the one gsf sell at the mo is pretty nice almost as nice as brickies one, both copies of the ATE one rather than the FAG which VW fitted which is poor

[xpress]

just a quick question hopefully an answer from those in the know, i was wondering about the union piece that goes into the clutch slave cylinder, it appears to have progressively fluted ends similar to a fuel petcock on an old moped where you can pull off the fuel hose and it's normally held on with a clip, is it the same kind of thing on the clutch slave, albeit without a clip?is it supposed to be in the flexi tube in a way that you can twist it out? hopefully you can give me some details on this, i can order another union piece. Maybe if i get it off the cylinder and put the flexi pipe end with the union in some hot water, i can free the union out of the flexi pipe? i got a small heating device from maplins to help coax the union out if that's what i need to do.

also do you need a socket and ratchet on both sides of the fixing holding the clutch slave to stop them from spinning around and around similar to a bicycle wheel hub?

[xpress]

bump, any takers?

[mrdp]

Hi not 100% sure what you mean but I can tell you when I changed my slave cylinder I didn't have To remove the union from the flexi pipe 'I did consider it at the time but decided to leave well alone union should unscrew from cylinder , hope this helps

[xpress]

update, i tried to heat up around the union as it goes into the clutch slave with one of these pos torches from maplin that take a cig lighter, but no dice. gave it a spray with wd40 with the straw, but nothing. going to try and heat it with a better torch and will get some pliers on the union. it started to round off so pliers are needed.

there seems to be only one bolt holding this cylinder on, managed to get that top nut to the top of the thread and there's movement there so it's only the union i need to crack. maybe it's a different design late/early differences?

i don't know if this cylinder even needs changing, a bit of surface rust on it but when i squeeze the rubber bellows, there's no presence of brake fluid and no fluid loss in the filler tank.

[xpress]

got one nut and bolt off, now the nearest one to the engine bay has to come off. the access is really poor. i have to try and get a spanner under that small box section to get on the head of the bolt, from underneath, then hold that while i turn a spanner at the top, over the engine bay. is there any easier way to get this bolt off? then the clutch slave should be able to be knocked off and new one put on.

[xpress]

bolts off and cylinder off mounting. now need to get flexi pipe off the union seized to cylinder because the union has been heated several times, sprayed and it won't come out of the cylinder. possibly different types of metal, and seized. it's rounded off and buggered anyway. so new union needed.