Input Cyliner Clutch Fail? (In-Depth)

[SeasSoShining]

Part references are hyperlinked.

The story: Hopped in car, pedal was sitting close to floor, and I really had to press it to shift. Shifted fine a few times and then completely stopped working.

Parked car at gas station. Pulled on the pedal, not too hard, but not forcefully, and the clevis on the input cylinder (1) came out of the assembly and boot... Drove other car to work.

That night I came back and popped the clevis back into the input cylinder. Shifted completely fine for about 50 miles. Dead pedal problem re-surfaced.

When I checked the reservoir, the fluid was sitting just below the port heading the to input cylinder. I refilled and brake fluid pours on the driver's side seat well as fast as I can pour.

The Gripe: I traced the leak to what I think is the hose/fitting (8/7) that connects to the input cylinder. It may need a re-snugging, or has a crushed plastic fitting (7), but I'm curious to see if anyone has ideas. I am concerned that the compression spring (22) attached to the clutch pedal assembly is contacting the hose. The part breakdown really is not clear on how this fits together (spring/hose). Despite peing able to pull the input cylinder apart I have a feeling it is not failing because the leak is near the hose connection.

Pictures:




Note:This is way more in depth than I needed to go, but before I order parts I am looking for ideas, or tips, from someone with previous experience... this looks like a pain in the ass the replace.

[Wanganstyle]

yes. total PITA.

you have a dead clutch MASTER cylinder. its made with many plastic garbage parts and likes to take a dump on you when you dont expect it.

the slave cylinder also is a pita and likes to sacrifice its life surrounding the master- so if you change the master and don't change slave also........it will die shortly.

change both slave and master, re-assemble and clean the carpet floor so the brake fluid doesn't destroy the footwell interior.

I have had these things fail in spectacular fashion, I hate them, always change in pairs now (lost a syncro @ wangan speed 1x....never again...)

you need to order at minimal;

1x master cylinder, 1x slave, and perhaps a new soft hose would be nice depending on shape of yours.

also, please check on wiring in your footwell area if you are going in there, look for weird butt connectors.....etc - non factory wiring modifications!!!

[Farbin Kaiber]

While you are doing this, I suggest replacing the hose, why not have a fully refreshed system? IIRC, blunttech sells all the stuff you'll need if you are looking for a one stop order.

[DrJosh]

You may have fixed this by now but I will reply anyway.

The exact same thing happened to me. The spring sits on a little indent a few inches above the hose. It worked its way loose and smashed the plastic elbow that connects the hose and the master. Chances are thats all you need to replace is the elbow. I took out the spring all together. I have very slight play in the pedal now but I figure its worth not having the spring go karawack on the hoses ass again.

I found it best to just remove the master cylinder all together and replace. You will need a 11mm wrench, 10 or 11 mm small socket, pliers and of course brake fluid and a new elbow.

Good luck!