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CessnaJon
Samba Member
Joined: August 15, 2008
Posts: 680
Location: Senoia,GA
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 Posted: Mon Sep 17, 2012 8:34 am Post subject: Clutch master cylinder clevis adjustment |
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I cannot for the life of me figure out an easy way to adjust the free play between the clutch pedal clevis/pushrod and the top of the MS piston. Anyone have a magic trick to this? I really would rather not remove the entire dash,if possible.
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1973 Westy (shared birthday)
1990 Westy Multivan
2015 Passat TDI 6sp
2015 Sportwagon TDI 6sp
LR-JET, Gulfstream 159 |
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r39o
Samba Polizei
Joined: May 18, 2005
Posts: 9800
Location: San Diego
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| Posted: Mon Sep 17, 2012 9:54 am Post subject: Re: Clutch master cylinder clevis adjustment |
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| CessnaJon wrote: |
| I cannot for the life of me figure out an easy way to adjust the free play between the clutch pedal clevis/pushrod and the top of the MS piston. Anyone have a magic trick to this? I really would rather not remove the entire dash,if possible. |
There is NO easy way. It is VERY difficult to get up there. Likely your pin is worn. Worn pins are the primary cause of slop. Also the hole in the pedal wears.
Take the pin out first and look at it.
Then if good, you can consider removing the plunger and putting in a vise.
But, that is usually not needed.....
All this is done from under the dash and is a pita.
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"Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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Thor-bob 
Samba Member
Joined: May 30, 2011
Posts: 36
Location: The OC
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| Posted: Mon Sep 17, 2012 10:15 pm Post subject: |
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Interesting.... I had to replace a master cylinder and repair a worn out clevis pin hole in the pedal, so I made a hole in the firewall behind the left headlight to access the clip on the BIG pivot pin for both pedals
I pushed the Big Pin to the right and dropped the clutch pedal. Remove the push rod and inspect the clevis pin hole.
At this point, you can weld and redrill the hole, then ream it for a close fit to a new clevis pin.
Reassemble the push rod onto the clutch pedal, and put some grease on the bushing area of the pivot (you DID check for wear here, right?)
Put the clutch pedal in place, slather grease onto the BIG pin and slide it back in place..... you can now check for free play of the push rod. Expect to do this a few times.
I found that there is an extra horn on the clutch pedal that is not used in this application - cut that sucker off and enjoy a way easier time of fitting and removing the clutch pedal whilst checking the free play.
when all is finished, cover the new firewall hole with aluminum tape for now and have a beer - you can do this repair later when the dash is out.
Thor
1990 Carat - 280 K miles |
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CessnaJon
Samba Member
Joined: August 15, 2008
Posts: 680
Location: Senoia,GA
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| Posted: Tue Sep 18, 2012 4:09 am Post subject: |
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SOLVED!
1. Remove 2 bolts holding in clutch MC, leave the plumbing attatched.
2. Moved MC to the left and down, separating it from the pushrod.
3. Push in clutch pedal (w/ left elbow)and slide a 5/8 spark plug socket up the pushrod and use a 3/4 stubby wrench on the hex of the socket.(guide socket with left fingers,wrench in right hand.)
4. Adjust!
This little guy is pretty sensitive to adjustment.Initially I gave it 4 turns out (longer) but this was too much. 2 turns was all it needed to take out the 1.5 inches of pedal freeplay before it actuated the MC. It did take reinstalling the MC a few times to get the adjustment just right, but the entire job was only about 30 minutes. Clutch pedal feel now is rock hard!
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1973 Westy (shared birthday)
1990 Westy Multivan
2015 Passat TDI 6sp
2015 Sportwagon TDI 6sp
LR-JET, Gulfstream 159 |
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yves rodrigue
Samba Member
Joined: September 12, 2010
Posts: 3
Location: quebec,quebec,canada
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| Posted: Mon Jun 09, 2014 12:45 pm Post subject: Clevis adjustement |
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Did the easy way to not say the lazy way.After spending lots of time trying to take out the pin i give up and deside to slot the bottom hole of the braket holding the master cylinder,now the adjustement not on the clevis but on the braket.The MC only holding by 1 bolt insted of 2 but it's work perfectly,no more pedal play and took me 1/2 hour to do  |
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