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Just did this on Sunday...
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Posted by Joe98 (more from Joe98) on Thu, 26 Apr 2007 09:14:42 Share Post by Email
In Reply to: Clutch problem, Todd inMA, Thu, 26 Apr 2007 06:26:12
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and your dilemma is exactly what I went through. I rebuilt my clutch mstr cyl over the weekend and it went quite well (except for what I wrote below).

What is happening is that air is being sucked into the feed tube (brake mstr cyl to clutch mstr cyl) from the point that you removed it when you took out the clutch mstr cyl. For me, it was at the bottom of the brake mstr cyl. You will need to tighten the clamp more, or get a new clamp (as I did--1/4"-to-5/8" hose clamp from auto parts store or hardware store. Forget the original style clamp as it does not tighten enough especially since these tubes are pretty old now). The tube is wet because it is leaking fluid out as it's sucking air in (from pushing down and releasing the clutch pedal). After you tighten the clamp, you will need to bleed the clutch system. I did it the old-fashioned way: open up the bleeder nipple on the clutch slave cylinder, have someone push down on the clutch pedal and hold it down, close the bleeder nipple, have the person let up on the clutch pedal, repeat until you have a tight pedal. Keep your eye on the fluid level in the brake mstr cyl and fill as needed to keep it at MAX. It takes a little time doing it this way, but it works. Be sure to attach a tube to the bleeder nipple and let the fluid drain into a small can or plastic bottle wedged down in front of the radiator. Brake fluid eats paint!

I found that I had to tap the clutch mstr cyl (handle end of a ratchet works well) as someone was pushing down and releasing the clutch pedal (bleeder nipple closed at all times). This allowed any trapped air or "stuck" piston inside the clutch mstr cyl to move. Once I did this, the pressure built up almost immediately in the pedal-feel.

Once done, take the car for a spin, using the clutch pedal as much as possible. I noticed the fluid level dropped after doing this, for whatever reason, and I had to add more. Do not use DOT 5 (silicone-based) fluid. Look for DOT 4, and if not, then DOT 3 is fine.

Good luck!

Joe
'93 900TC 156K
'98 9000CSET 112K

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