Norma66-Brent
Norma66-Brent HalfDork
5/5/22 10:02 p.m.

Get it!

wawazat
wawazat SuperDork
5/5/22 11:22 p.m.
Noddaz said:

I am glad to hear your Dad is doing better...

What did Malwood say?

Thank you.  I am as well!

The new axle shaft Malwood uses for pedal mounting appeared too short as I had previously converted my pedals to needle bearings as the OEM plastic bushings failed years back. I was concerned about pedal motion but this isn't an issue as they only use the axle as one mounting point for the new clutch pedal assembly.  I'll get some pics tomorrow during reassembly to show what I saw.

wawazat
wawazat SuperDork
5/10/22 1:56 p.m.

I continue to hold that the most hateful place to work on a car is under the dash.  Blech!

After assembling the pedals I spent way too long trying to get the whole assembly in place with no success.   Backing up a bit I blew apart the pedal assembly to install things individually.  This enabled me to get the pieces back in but made for challenges to assemble things way up in her guts while upside down and trying to do three things at once.  I got the upper clutch pedal bolt in.   I had to adapt the MC fitting from -3 to -4 then add a 90 -4 elbow to help route the line to the slave cylinder.  Tonight is finish the clutch pedal mount then install the brake pedal then the column and MC reservoir to start fill and bleed the system.  

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
5/10/22 2:46 p.m.
wawazat said:

I continue to hold that the most hateful place to work on a car is under the dash.  Blech!

working on someone else's toilet is pretty gross, but upside-down under a dash sucks too!

 

wawazat
wawazat SuperDork
5/11/22 9:12 p.m.

Back up to theee pedals again.  

wawazat
wawazat SuperDork
5/11/22 9:19 p.m.

To get the clutch pedal in I needed to add a 90 -4 coupler and one longer bolt.   Sounds easy when I type it but wasn't much fun working mostly blind in that area.  My older son gave me a hand with one bolt.  After fighting to start the second bolt I tried a longer one that finally started in to the threaded axle shaft.  As I had neither the fitting nor the fastener on hand I had to pick them both up in separate trips.  Everything is in place now including the reservoir.  

wawazat
wawazat SuperDork
5/12/22 9:10 a.m.

wawazat
wawazat SuperDork
5/12/22 9:12 a.m.

Then I went all in on NVH mitigation with these two.  


 

wawazat
wawazat SuperDork
5/13/22 3:41 p.m.

After dark the other night I locked down the master cylinder and the pedal bracket.  Next day I saw the brake pedal was way WAY up there so last night I modified the two piece adjustable pushrod to drop the pedals back in to correct position.  I just reinstalled the brake light switch assembly and filled the clutch MC.  Bleed process starts as soon as Ms. wawazat and the WK1 and WK2 get home from school. 

wawazat
wawazat SuperDork
5/13/22 3:47 p.m.

I'm a bit apprehensive right now.  Should things bleed and then release the clutch it'll be time to celebrate.  Should things bleed and the clutch not release I'm thinking the trans may have to come out again to index the pivot ball forward again.  
Another possible solution Brent (Norma66) and I discussed was indexing the slave cylinder forward a bit.  I can do this without pulling the trans and should clutch not release I'll give that a whirl before getting my despondent on.  

wawazat
wawazat SuperDork
5/13/22 3:48 p.m.

Brake pedal on Viagra 


 

surprise

wawazat
wawazat SuperDork
5/13/22 3:51 p.m.

Brake pedal mods to pushrod 

 

wawazat
wawazat SuperDork
5/13/22 3:59 p.m.

The rod going in to the brake MC-red skinny arrow-is held in place with a rubber bushing and probably won't ever come out.  The rod with the yellow arrow is much easier to access so I pulled it.  I pulled the coupling nut off and cleaned the thread lock off the rod and ran the nut down to the end of the threads.  This got me headed in the right direction.  As I had about 3x OD of thread engagement on this piece I cut some off and fully fit the coupling nut in place.  I then cut some off the coupling nut and reinstalled it.  Some thread file touch-up and things fit well and at a good pedal height.  
 

better but needs to be lower.  
 

That's better.  As the elevated pedal didn't last for more than 4 hours I didn't need to call my doctor.  
 

 

wawazat
wawazat SuperDork
5/13/22 5:55 p.m.

WTF is going on with this thing?   I've got a buddy over and we've bled the system.  May not be 100% but last 6 fitting breaks have  nothing but fluid leaving the nipple.  I'm only getting a fraction of an inch of slave cylinder travel.  No leaks on either end-master or slave cylinder.  Front side of the slave cylinder piston is dry so seal isn't letting fluid around the piston.

I'm baffled as to what's happening.  It may still be air in the system.  That's the only thing I can think of causing this.  

Shavarsh
Shavarsh Reader
5/13/22 6:41 p.m.

Hope its just a bleeding issue, enjoying the pictures of your progress. You just reminded me that I have no boot on my brake pushrod!

wawazat
wawazat SuperDork
5/13/22 7:11 p.m.
Shavarsh said:

Hope its just a bleeding issue, enjoying the pictures of your progress. You just reminded me that I have no boot on my brake pushrod!

Thanks man.   I'd feel a LOT better about this if I could get this resolved.  
Thinking this through though I don't think I'll need to drop the trans again.  Im not getting pressure at the slave cylinder so no travel.  If I can get the travel clutch should release.  I'm getting 1/4" or so and the slave has 3/4" stroke.  
Since my last post I've jacked up the back of the car to help get any trapped air closer to the bleed nipple.  I had the nose way up for access underneath.  Car is now level though engine is tilted down by design so slave is still slightly tilted up away from bleed nipple.  I'm going to bring the nose down and get under it from behind and see if that will move any trapped air out from behind the piston.  

wawazat
wawazat SuperDork
5/13/22 7:18 p.m.

The system is just not building pressure when I depress the pedal.  None.  Im getting fluid flow through all the components-reservoir-master-slave-but no pressure so no slave cylinder travel and no clutch release.  I know air will compress so pressure won't build and that's the only thing I can think of now.  

Shavarsh
Shavarsh Reader
5/13/22 7:40 p.m.

The pedal isn't hitting the floor before maximum master travel is it?

wawazat
wawazat SuperDork
5/13/22 8:37 p.m.

Nope. Full pedal travel with no obstruction.  No leaks anywhere-not on the master cylinder lines nor on the slave cylinder lines.  No fluid on the front of the slave cylinder piston so I don't think that is bad. Leveling  the car didn't help.  
I'm going to compress the slave cylinder fully to minimize its fluid volume then pressure bleed with a large syringe then with compressed air if the syringe method doesn't work.  I've got lots of fluid!

wawazat
wawazat SuperDork
5/13/22 9:52 p.m.

Thanks for the consult tonight Michael!  Good talking to you.  
WK2 and I are picking up my Mom for a trip to her favorite garden center for her annual flowers followed by lunch.  Tomorrow afternoon I'll try some pressure bleeding methods and a gravity bleed Michael suggested.  

Dusterbd13-michael
Dusterbd13-michael MegaDork
5/13/22 10:32 p.m.

Good luck! Its close. Just a matter of the last little bit. 

TurnerX19
TurnerX19 UltraDork
5/13/22 10:40 p.m.

The trouble here is probably that the total volume of the plumbing is greater than the displacement of the master cylinder. Along with possibly a high spot somewhere for the air to hide. Pressure bleed it from the reservoir with the slave oriented as well as you can. 

wawazat
wawazat SuperDork
5/13/22 11:48 p.m.

Thanks again Michael.  Thank you Turner.  Back at it tomorrow afternoon.  

wawazat
wawazat SuperDork
5/14/22 7:26 p.m.

Pressure bleed 5x thru the reservoir didn't get it-some bubbles but no pressure build.  I've pulled the slave and elevated it to now be highest point of the system.  I'll crack the bleed screw later tonight after clamping the piston rod to keep it from blowing out of the cylinder and see what that gets me.  
Tech guy from MC supplier agrees that there is air in the system.  Advised to go to hydraulic throw out bearing as a better system for a bunch of reasons.  He did offer some tips to isolate the problem which he fully believes is the slave cylinder.  I'm not done trying to bleed the slave cylinder yet.  I'm not ready to go to hyd TOB as that means trans must come out again and I'm really hoping to avoid that.  

jfryjfry
jfryjfry SuperDork
5/15/22 2:06 a.m.

You can also use a large veterinary syringe to push fluid into slave cyl and up to the master. 

Can you pull the slave off and watch it operate?  If it's only moving the clutch 1/4" maybe the clutch is jamming?

Our Preferred Partners
UpFo5aQxflPxbQwSEtmf8EPCZ4VKPgnxR4FMivEAcMd8EyAud6V51LNApg0nKrtu