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BrownLoaf
Samba Member
Joined: January 21, 2021
Posts: 94
Location: Bellingham, WA
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 Posted: Thu Jan 06, 2022 7:38 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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| ZsZ wrote: |
There are the ATE designed cylinders (short pin) and the FTE designed cylinders (long pin). Both have the same overall working dimensions.
The problem occurs when parts are mismatched.
Most of the aftermarket cylinders are the copy of the ATE version. |
This is good information and may explain the three cylinders I have. Here's a summary of them with sources, as requested:
A: 2013 purchased at FLAPS (no reciept-likely to have been O'Reilly's or NAPA). Medium in length. Transmission would sometimes grind into reverse and 3rd gear. Possibly an ATE rebuild.
B: 2021 purchased at O'Reilly's (lifetime warranty). Shortest in length. Transmission would not go into any gear. Possibly an ATE rebuild using a deep socket piston from an FTE (mismatch of parts).
C: 2022 FTE "gold standard." Longest in length. Transmission shifts smoothly into all gears. Time will confirm if there is ever any grinding into reverese or 3rd (I expect none since the clutch pedal finally goes all the way to the floor).
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87 Vanagon Syncro Tin Top WBX 2.1 "Bubbles" |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 3019
Location: MD
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| Posted: Sun Jan 16, 2022 10:29 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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The FTE slave is back ordered everywhere. My rebuilt transmission shifts really smoothly, but I have to really push down on the pedal. There's like this 95% travel detent and then the 100% travel full stop. And it takes a lot of extra effort to get to 100%. I have to push my toe in. I haven't experienced this in 2-3 and 3-4. But it's a lot more noticeable in N-R and 1-2.
I had forgotten all the little extra actions I took when shifting while it was sitting without a trans. A rebuilt trans shifts so easily.
If I had a machine lathe I might try the cut and weld approach. Not sure what to do. This is really annoying because I just bought a slave cylinder from Bus Depot and it had the wrong piston. Now I need to buy a second one.
There are a few on eBay, but eBay can be a crapshoot when it comes to name brands. I'll give it a shot if no one has any other ideas though.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 9603
Location: Western WA
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| Posted: Sun Jan 16, 2022 11:24 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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I assume a guy with a shop-lift has done a bleed-check, right? 
| 4Gears4Tires wrote: |
| other ideas ........ Not sure what to do. |
You have the best idea already. cut, extend, weld but skip the lathe.
It will answer your Qs in a few minutes.
And never lift that boot for anyone.
Saving your new synchronizers starts at that moment.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 3019
Location: MD
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| Posted: Sun Jan 16, 2022 11:37 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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Bleed done, yeah. I'll do it again when I mess with the piston I suppose.
The trans has 110 miles on it so far. 90 more and I'll replace the filter and change the oil.
Definitely have a 90mm one. Dobryan has a 100mm version that I will swap in. I'll post back if that makes a difference.
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 3019
Location: MD
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| Posted: Mon Jan 17, 2022 7:33 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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Dobyran gave me a spare slave cylinder piston. Going into reverse was noticeably easier, the roads are far too salty for checking the 1-2 shift. But I will update when I do. I rebled the clutch after checking and that didn't make any difference. The cup on the longer piston is 1mm deeper, 11mm vs 12mm.
One thing I noticed with both slave cylinder pistons was how much the slave cylinder bracket moves. That doesn't look right at all! Can anyone confirm if their bracket moves? I'd imagine that this thing should be rock solid. In any other vehicle I've had they're solidly mounted on the transmission housing and there is zero flex.
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dobryan
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Joined: March 24, 2006
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Location: Brookeville, MD
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4Gears4Tires
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Joined: October 08, 2018
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Location: MD
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| Posted: Mon Jan 17, 2022 7:44 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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That's good to know. I might try to reinforce that bracket a bit.
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dobryan
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4Gears4Tires
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Joined: October 08, 2018
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Location: MD
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| Posted: Mon Jan 17, 2022 8:38 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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Yes it does. That's what I was thinking about reinforcing.
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BrownLoaf
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Joined: January 21, 2021
Posts: 94
Location: Bellingham, WA
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 9603
Location: Western WA
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| Posted: Tue Jan 18, 2022 11:17 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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| 4Gears4Tires wrote: |
| Yes it does. That's what I was thinking about reinforcing. |
Do some vans have a brace on that bracket?
_________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 3019
Location: MD
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| Posted: Tue Jan 18, 2022 5:02 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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| Sodo wrote: |
| 4Gears4Tires wrote: |
| Yes it does. That's what I was thinking about reinforcing. |
Do some vans have a brace on that bracket? |
Yes. It bolts right near the cv axle.
I was thinking of using the same bolt hole to the trans, but then attaching a similar brace to the outside of the bracket. Then connecting the two.
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Sodo
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| Posted: Tue Jan 18, 2022 11:55 pm Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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I’m sure that will stiffen it.
I see you drilled an access hole for a ball-allen wrench.👍🏽
So do all years have that brace?
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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dobryan
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Joined: March 24, 2006
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Location: Brookeville, MD
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BrownLoaf
Samba Member
Joined: January 21, 2021
Posts: 94
Location: Bellingham, WA
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| Posted: Wed Jan 19, 2022 6:59 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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| dobryan wrote: |
| Sodo wrote: |
So do all years have that brace? |
I know from experience that '87 -'91 have it. Not sure about prior years. |
My 83.5 has the brace.
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83.5 Vanagon Riviera WBX 2.2 "Brown Loaf"
87 Vanagon Syncro Tin Top WBX 2.1 "Bubbles" |
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revolution337
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Joined: May 23, 2009
Posts: 372
Location: Pennsylvania
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| Posted: Wed Jan 19, 2022 7:13 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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| loganthecyclist wrote: |
| dobryan wrote: |
| Sodo wrote: |
So do all years have that brace? |
I know from experience that '87 -'91 have it. Not sure about prior years. |
My 83.5 has the brace. |
My 1982 aircooled also has that brace.
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danfromsyr
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Joined: March 01, 2004
Posts: 15143
Location: Syracuse, NY
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| Posted: Wed Jan 19, 2022 7:43 am Post subject: Re: Travel of Clutch Pedal - SOLVED! |
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they are ALL supposed to have a brace
but years of prior owners and mechanics any particular van could be missing it. and a new/fresh owner unaware. till the mount breaks and the clutch quits.
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| These are the reasons we have words like “wanker” |
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