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Thanks guys for your helpful responses.
I started on the job again this morning and opened the line from the master cylinder to the slave cylinder at the joint above the gearbox. I then applied pressure to the top of the reservoir and a very tiny trickle of fluid eventually emerged. In that fluid I saw tiny black specks which I guess was the rubber balls referred to in previous posts.
I then set about removing the master cylinder and lines. It might be an easy job on left hand drive cars but I can tell you it not easy on a right hand drive car. Access is difficult and the line of vision to the cylinder is poor. Never-the-less I struggled on and got it out.
The first thing I noticed was this black coloured syrup dripping from the rubber hose connecting the master to the reservoir. This is despite having completely flushed the system yesterday. The other thing I noticed was that the piston in the master cylinder was in the depressed position and was not returning under spring pressure to the back of the cylinder.
I guess the master cylinder piston is jammed with little pieces of rubber.
Having determined the hose is perished I have removed all the other similiar type hoses that lead to the brake master cylinder and ABS and I will replace the lot.
Next thing to do will be to give the slave cylinder a very good flush to get the gunk out of it.
Due to the very high cost of master cylinders in Australia I have bought a kit of rubbers to recondition the cylinder.
One of the things I have learned from this exersize is that when you are reinstalling the gearbox, it is VERY ADVISABLE to connect the hydraulics to the gearbox and see if everything is working as soon as you have bolted the gearbox to the engine and before you start reinstalling the sub-frame and suspension strut.
The other worry I have to address now is whether I installed the clutch release bearing correctly. I can remember prying the old bearing off with screw drivers on each side. However, when I put the new bearing back, it slid over the inner guide but didn't specifically lock in place. I then reinstalled the gearbox thinking the bearing was in the proper position and couldn't go anywhere.
Can someone give me some guidance as to whether I have to remove the gearbox again to put that right.
Regards from Australia.
posted by 203.26.24...
, Sun, 31 Oct 2004 09:39:19
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