1991 Syncro 16' clutch locked up in San Blas, MX

INDTUBE

After 5 days of straight driving from CO (on my way to Costa Rica for the winter) my Clutch locked (Can't push it to the floor) in San Blas, Mexico. The mechanic said he could find the part (new Clutch) but I fear that he has never worked on a Syncro before. Any advice or help on replacing the Clutch would a huge help?

Not sure why it would have gone out - I did allow my friend to drive for 30 minutes in route and he mistakenly left the emergency brake up and drove for about 20-30 minutes not realizing the brake was up. I assume this would effect the brake shoes but could this have destroyed the Clutch as well? and what effect could this have on the VC? At this point I am bit scared?

thanks in advance?

SyncroGhia · Posted: Sun Nov 25, 2012 3:48 pm Post subject:

Your brakes will not have made any difference to your clutch.

The only things that I can think that would create a clutch pedal that won't move is either that the pedal mechanism and master cylinder have failed - check up by the pedals or that the slave cylinder, rod or clutch release bearing arm (the most likely) has failed.

It will be possible to drive it further without being able to dis-engage the clutch but it takes a skilled driver to be able to change gears successfully without crunching through gears.

MG
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INDTUBE · Posted: Sun Nov 25, 2012 4:06 pm Post subject:

kgold708 · Posted: Sun Nov 25, 2012 4:38 pm Post subject:

Where was the thing he loosened to let the fluid out located?
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INDTUBE · Posted: Sun Nov 25, 2012 5:28 pm Post subject:

On top of the rear transmission he loosened the metal tube that goes into the clutch slave cylinder

insyncro · Posted: Sun Nov 25, 2012 5:32 pm Post subject:

My guess your throw out bearing is binding or the clutch disc has fallen apart.

INDTUBE · Posted: Sun Nov 25, 2012 5:50 pm Post subject:

Thanks so much! So what do I have to be concerned about while he is doing the work. How difficult of a job is it? and how bad can he screw up my my van?

0to60in6min · Posted: Sun Nov 25, 2012 5:56 pm Post subject:

he won't put it worse as you are now if he put everything in order as he removed.. make sure that he bleed the whole system correctly...

insyncro · Posted: Sun Nov 25, 2012 6:10 pm Post subject:

Syncrozilla · Posted: Sun Nov 25, 2012 6:32 pm Post subject:

There is another possibility. The throw out bearing cross shaft could have broken an arm. Clutches don't usually break in a single event. If the pedal is up and won't go down then it's unlikely that there is a failure in the hydraulic system. Broken cross shafts are very common with the older air oiled VWs and less so on vanagons. Still I have seen this happen a few times at it will present itself as a instant event. You kind of have to know what your looking at but if you pull the rubber Boot off the rod on the end of the clutch slave and the piston is all the way at the end of its travel this is most Likely the cause. If this is the case the clutch pedal won't depress because the piston on the slave is already fully extended.
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Syncrozilla · Posted: Sun Nov 25, 2012 6:35 pm Post subject:

I should have read this thread a little better before posting. I see that syncroghia already suggested the release bearing arm.
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Wildthings · Samba Member Joined: March 13, 2005 Posts: 52379

Are all the fastener present in the slave cylinder mounting bracket? The lever arm on your clutch release shaft may also have cracked. Either of these could be easily checked with the engine and tranny installed.

dhaavers · Posted: Sun Nov 25, 2012 9:11 pm Post subject:

If you're unsure of your mechanic, see if he'll let you walk through it with him.
This worked for me (first timer - no prior experience):
http://volksweb.relitech.com/clutch.htm
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IdahoDoug · Posted: Sun Nov 25, 2012 9:53 pm Post subject:

Indytube,

Looks like some good advice here. If the mechanic has done Vanagon clutches and is good at it, the Syncro trans is not different enough to be concerned about his ability to tackle it. A couple things will frustrate the crap out of him (tight up there where the starter is against the fuel tank, etc), but I'd say 2wd clutch jobs done well qualifies him for yours.

I also agree I can't see the parking brake being related.
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INDTUBE · Posted: Mon Nov 26, 2012 1:37 am Post subject:

Can't thank you guys enough! Given that its the weekend - I should know more tomorrow when he actually begins the work. The key now is to be able to locate a new Clutch kit.

As a side note - This is my first driving trip down to mainland Mexico (I have done Baja a number of time) and can report that I feel totally safe and have nothing but good things to say about Mexico and the people that live here. No problems with Federales, no one is shaking you down for money, I have found the police to be nothing but professional and helpful. I ran into another guy from LA driving his westy to Argentina and he was having problems with his van and the police towed him to the closest mechanic.

INDTUBE · Posted: Mon Nov 26, 2012 3:42 pm Post subject:

Ok so we are having a real problem locating a new Clutch kit. . . The mechanic says he can rebuild the old one with a new set of bearing. Can this really be done? and if so how long can I expect it to last? I think I have come to the conclusion that if a new clutch cannot be located that I will have to limp back to the US and if they are able to find a new clutch I can continue on my journey. Any advise here would be most appreciated.

Escorial Syncro · Posted: Mon Nov 26, 2012 5:25 pm Post subject:

Are you still running the 1.6 turbo diesel? If so the issue might be finding the diesel clutch, which is different than the gas clutch. Your mechanic might be saying he'll install a throwout bearing to address the problem. The throwout bearing is a more common part, shared by both diesel and gas vanagons, IIRC. Might fix it, but given the miles you have to go perhaps a fresh clutch kit is in order.

You can order a diesel clutch kit from multiple sources, this being one of them: http://www.busdepot.com/

Order, while it ships you drink/surf. Hope that helps.
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crazyvwvanman · Posted: Mon Nov 26, 2012 5:31 pm Post subject:

If you looked at the prior responses you should know that fixing your problem may require important parts that are not included in a complete clutch kit. What will you do then?

Mark

Wildthings · Samba Member Joined: March 13, 2005 Posts: 52379

Assuming you have a WBXer with a 228mm clutch, I don't think VW ever used that size clutch in Mexico. When I blew an oil galley plug on my 1800 years ago near Cuidad Valles, it took me several tries to find a shop that had the correct lining to rebuild my disc for me, but I was able to get it done.


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