Saturday, May 29, 2021


Now that the car will run without leaking vital fluids, it's time to make it shift and stop.  I started with the shifting part, because it's easier.

The paperwork I have indicates the clutch master cylinder was replaced, so I figured it would be okay inside and that a rebuild would bring it back to life.  So that's what I bought.

First things first as always is to get the thing out of the car.  Wow.  I wouldn't want to do this twice.  I am sure I did it the hard way, but I can't see an easier one...

To remove the clutch master cylinder, I popped the firewall plug to gain access to the fixing bolts.  Then, I removed the banjo from the back.  Nothing leaked out, but that's because it leaked out the bottom (slave) long ago.  

Then I removed the box cover and the clevis pin attaching the pedal to the master.  That was the easy part.

Getting those two nuts and bolts that hold it in place was a bear.  The top one was easy since it was right on top.  The bottom one was horribly difficult, even with passing a long extension through the hole in the firewall apparently designed for this purpose.  With the dash in place, it was really hard to get the extension/socket and wrench all together, but I eventually did get it done and got the master cylinder out.

I also found the lead to the brake master cylinder pressure failure switch, which isn't hooked up because there is no switch installed (it's plugged with sealant).  I'll deal with that later.

The master cylinder is really simple and easy to rebuild.  The bore is spotless, but one of the seals looked like it failed or was failing.  No matter - the rebuild kit has all the stuff.

Reassembly is simple and just means putting all the stuff back the way I found it, with the new parts of course.

Installation into the car was not as difficult as removing it.  I found the right angle to get a socket on the bottom nut, so I didn't have to go through the hole in the firewall.  Easy-peasy.

On to the slave cylinder - 

This of course means getting under the car.  Ugh.  This is what I saw.

Fortunately, everything came out relatively easily.  (I continue to have good luck in this area.)  Replacement is simple - after a good clean, a new hose and cylinder fit right in place.  The cleaning took the longest.

I only cleaned the half I worked on, so there's definitely more to make nice under there.

I think I have a little problem though, easily remedied, but wow.  Take a look at the pin and pushrod.  There's been "some wear".  They'll work for the moment but need replacing.

Once assembled, I bled the system.  This took a while even with my vacuum bleeder, but I did finally get a good first bleed done (and the fluid is clean - so nice.)

I have a clutch!  I can push the pedal and move the car while in gear, and for a final test I fired Alice up and "drove" her about 2 feet.  She moved under her own power for the first time in at least a decade.  Once I replace the pin and pushrod, the pedal will be where I expect.  I'm also happy that the clutch disc wasn't frozen and there was no juddering.  One more thing I don't have to do!

I'll bleed the system again eventually, but for now I have one fully functioning clutch, and Alice is one step closer to being on the road.

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