Join Date: Jul 2008
Location: Hornchurch, Essex
Clutch arm bent? HELP!!!
OK I seem to be cursed. Had leaking clutch hydraulics so bought a new kit of master and slave cylinder. Then I had all the fun of removing the old ones... I was a bit surprised by the stiff plastic hose too, so decided to replace that with something bullet-proof, as I do NOT want to ever do this again.
Measured the old hose and it was longer than the Goodridge one available for the Sud. So I sent off the old hose and had one made up. Except that they used different end fittings, which mean the hose makes a very tight radius bend now, between the master and the bulkhead (in my Minari). Also had to enlarge the bulkhead hole, plus use a copper washer on the master cylinder fitting, as the thread is too short for the taper to bottom out in the cylinder.
Anyway, time to put it all back together. More fun with the slave circlip, even with my new very expensive circlip pliers. Then disaster. Circlip pings off, stragiht down inside the bellhousing! Not possible I thought. Finally discovered the removeable plate on the underside of said housing, removed it and circlip fell out. Big relief. Fitted everthing, bled it and tried it out. Felt funny so I pumped it a few times. No change so out for a look. Disaster! Slave piston has over-extended, ripped the seal and sprayed DOT4 EVERYWHERE.
Big cleanup, dis-assemble again... turns out the internal circlip in the slave was missing, so piston shot straight out. Bigger problem. Because the pushrod was pushed further than intended, it seems to have bent the clutch arm. So the arm is now quite floppy and cannot disengage the clutch, as its usable travel is now minimal.
Can I get to anything usefull without removing the gearbox?
If I try to bend the arm back, with a tyre lever, will it work? Will it be safe to use? Will any real engineer ever speak to me again?