Clutch slave cylinder overhaul #1

On one day before I started the repair of my onboroALFA, when I pushed the clutch pedal, I felt the feeling like something was bursting at my feet and the clutch pedal lost the reaction force suddenly. Then, I recognized the slave cylinder of the hydraulic clutch became useless.

At that time the brake calipers were also perfectly sticking. So, it meant all of the hydraulic system of my onboroALFA was dead.

The overhaul of the brake calipers was finished, however, I had to repair the brake master cylinder, clutch master cylinder and the clutch slave cylinder yet. At this time I started the repair of the clutch slave cylinder. I would remove the clutch slave cylinder and checked whether I could overhaul it or I should replace it with a new part.

This was the status at this moment. The cylinder piston popped out and the boots came off. It was rusty and looked very bad condition.

At the front and rear side of the clutch slave cylinder there were 2 snap rings that were fixing the slave cylinder to the clutch housing. In order to remove the clutch slave cylinder these 2 snap rings had to be removed.

Snap rings were removed. It was very dirty…it was impossible to work properly with this condition.

I separated the hydraulic hose from the body. The fixing of the hose was very tight and it took time to loosen it. The size of the flair nut of this part was 15mm that was unusual and same as the brake hose flair nuts. The color of the brake fluid was terrible.

I tried to remove the slave cylinder from the clutch housing. However, it was not easy because the slave cylinder was sticking by rusts. I removed rusts by scratching with a screwdriver. After several tries the slave cylinder could be removed.

It took 3 hours to remove the slave cylinder. By this moment I thought that I had to replace the slave cylinder with new part.

However, after cleaning the removed parts, I found the slave cylinder itself looked good. The rust seemed to come from the spring part mainly. I would check the slave cylinder whether it could be reused or not. I believed that the quality of the genuine part was much higher than the third party’s reproduction part. So, I would like to overhaul and use the original part if it would be possible.

(My original blog was written on 13th Apr. 2009)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Pad spring repair

One of the springs to hold the brake pads was broken. At first I thought to buy it, however, I tried to fix it using rivets. It seemed to be strong enough just to hold pads. Later I removed the rust and cleaned them. Note: I have been using this repaired pad soring for 10 years and there is no issue. Pad spring is not an expensive part ptobably (I don't know the exact price), but it is easy to repair if you have ar1750gtv hand rivetter. (My original blog was written on 10th May 2008 )

Body repair around the fuel tank

I found some rust at the flange in body around the fuel tank as I expected. I believed this level of rust in this area was quite usual for old Alfa Romeo. It seemed that this area didn ’ t influence on the body strength , however , I was considering the method what I could do by myself. Anyway in order to prepare the sheet metal for the repair at first , I started to look for the store where I could buy some sheet metal near my house. I tried to research the store on internet , but I couldn ’ t find appropriate stores. Finally I asked the person at repair shop , who did maintenance of my Renault 5 , about the store I could buy some sheet metal. They kindly taught me the store , but at the same time they gave me some sheet metal for free. That was enough volume for what I wanted to do. I didn ’ t expect it. Thanks a lot!!! (My original blog was written on 12th Sep. 2008 )

The day my "onboro ALFA" would revive

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