So I thought I would try bleeding the new clutch hydraulic system one more time. In my third week trying to get the clutch slave cylinder bled. Yes, I have read every thread - and there are a lot of them- about the @#%ing clutch slave cylinder.

Before I call l the car crusher again: (1) Is there any reason why new banjo bolt crush washers will not seal? New crush washers, lots of torque, little torque, etc etc. and it literally drips when not even pressurized. Until that problem is resolved, I don’t think bleeding is going to do a lot of good. The old, rusty slave cylinder didn’t leak a tad. (2) Should I remove the Commodora Daytonas before it goes to the crusher?

All this talk of folks replacing their hydraulics lately and doing it in a few hours has really started to get me worked up.

LarryC, Albuquerque, New Mexico

When it comes to bleeding just take your time. When I did the cluch I would say I used a at least 1 1/2 times the amount of the reservoir. Not sure about the other problem.

Our cars are related

....don't loose faith! It takes a while but it'll be worth it, right?

if not then sell the Daytonas to me!

would be an awful waste to crush it. sell it or just back off for a few days and give it another shot. that always works for me.new washers and it wont seal, thats a new one for me. id asume the hose end and slave cylinder are clean, come to think of it, when i installed aftermarket hoses on my front brakes, i had to double up the washers due to the fitting being thinner. that should solve your problem.

reyy
longtime fiat freak
74 x1/9
san dimas, ca
USA

Actually, I am in kind of a mood for taking a solo road trip in the X that I could get to within a days drive. Ever made the drive from PHX to Alb? How long is it? I got some spare parts you might could use...

I am having my dog eutahnized on Monday, so I could really stand to get away for a few days...

Tommy

I am just pretty bummed about my dog...

Tommy, there is nothing any of us can say to make you feel better right now.
But keep in mind that the only thing sadder than losing our friends would be to have never shared our lives with them at all.





I lost Paisley in 2001 and Sam in 2003 after less than a year. Lady arrived in 2003 aged 9 years and she likely won't see another Summer. But I wouldn't trade away a day with any of them. Hang in there, Tommy.

Charles

I am now trying to balance my grief that she has passed, with my relief that she is no longer suffering from cancer.

But I already miss her dearly, and my other dogs do to, or so it seems.

Cheers
Tommy

Sorry to hear of your loss.

Assume the new slave is just a poorly made POS.

Get another one.

I had a terrible time getting mine bled. I ended up replacing it and still had the same problem.

I think what finally worked for me was disconnecting the slave from its mount, and allowing the piston to come out more than it normally would. This gives more room in the cylinder. Then I opened the bleed screw and pushed the piston in, then closed the screw.

MikeR

Usually new copper washers are PLIABLE enough to make up for all the little idiosyncrisies but if they are NOS... they could get HARD with age.

I've re-used old washers by FLAT sanding them to gain a new flat surface... and if you HEAT them with a torch... then you essencially will anneal them back to being soft also.  You might also FLAT FILE or sand the banjo-bolt and or the mounting surface to repair any imperfections there also.

You must fix all the leaks first... but as I said before... if you are indeed doing everything right... then the problem is in the slave or the master.  We've seen and heard of NOS stuff not being any good before.

Again... sorry for your trouble... maybe encouraging Tommy to take a trip out there would be beneficial to you both.

My best,



Tony
Black Tooth and me... since 1983!


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The problem could be due to a tiny scar, pit or other similar problem on the sealing surface. All it takes to cause a leak is a tiny surface defect and the crush washer will not seal.

Check all sealing surfaces very carefully. If there are any problems with the sealing surfaces, do what is needed to fix this first. This could mean replacing or a little machine work on what ever is required to get a proper flat smooth sealing surface.

Use new copper/aluminum crush sealing washers or anneal the old copper ones if they are to be re-used. Do not over torque the banjo fittings or they can leak and cause other problems.

One possible solution is to use a O-ring in a washer type of banjo fitting seal. These are available from your local industrial fitting supplier or Mc Master Carr p/n 93786A200. The clutch banjo fittings size is M12.

I can give you a hand. 261-5477

Roy
81x
86 Shelby GLHS #200
87 Shelby Lancer #781
85 Honda Interceptor 500
Albuquerque, NM

Thanks for all the support.

Recall from my message from aweek or two below that I had just pulled the pedal box and replaced and repainted all. New masters. New hoses to the reservoirs, too. Both masters bled and pumping. Brakes bled and working. Clutch slave refuses to bleed.

The best so far is ¾ inch of clutch slave push rod travel. That was just before I realized that the clutch system leaks at the banjo bolt where it is attached to the slave cylinder. Leaks with or without pressure. Having done the hydraulics on many older vehicles over the decades, I have picked up a lot of tricks for dealing with these problems. And I worked through most of the obvious answers to fix leaks like this one.

But this one takes the prize: New copper washers, clean mating surfaces, taking it apart and reassembling multiple times, very carefully, with and eye on everything fitting correctly, and scrutinizing the surfaces for micro-cracks that might be opening on torque. Nothing results in a good seal at the banjo bolt. These efforts over many days only succeeded in moving the leak from one side of the flex hose banjo mating surface to the other.

The moving of the leaks from one side of the banjo fitting to the other makes me suspect that, just maybe, the two flat sealing surfaces on the banjo bolt end of the flex hose are not machined parallel to one another, and that the copper washers are not able to accommodate the corresponding gap.

Me, too. I have never heard of such a thing. I tried putting a micrometer on it, but got ambiguous results. So, I will try another new flex hose because there is not much else left. This project has become one of those.

,,,,

I can only sympathize. I happened to replace my slave hose when I replaced the slave, so I cannot compare experiences. Good luck!

Gregory Smith

'87 Bertone X1/9 Corsa
'88 VW Vanagon
Olympia, Washington, USA
http://gregoryfsmith.com