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clutch lever arm wear
https://www.ausmini.com/forums/viewtopic.php?f=2&t=40212		 Page 1 of 2
Author:  whiteski [ Sun Mar 16, 2008 12:27 pm ]
Post subject:  clutch lever arm wear
Background

My clutch was dragging and it got to the stage where I had trouble putting the car into gear. I bled the clutch hydraulics. There was some air. Once bled, I could select gear, but there was a little bit of drag. Four weeks later the aforementioned situation happened again. I bed the clutch again, there was some air bubbles, however this time, once bled I could NOT select gear at all, even with the clutch pedal flat to the floor.

Check 1

Checked the clutch pedal clevis and pin. There is some slack, pehaps 1 inch worth of pedal travel.

Check 2

I clamped the hose between the clutch MC and the SC and pressed the pedal and it was rock hard, suggesting the MC and hose are ok, but the SC might not be functioning at 100%. (Thanks to Simon K for his help)

Check 3

I removed the clutch lever arm and checked the ball at the end. The ball is worn flat on one side, the contact side. This can be seen in the photos shown below. The contact surface is very highly polished.

My question

Is this wear on the clutch lever arm sufficient to cause the problem of severe clutch drag and trouble selecting gear or is it "within tolerances"? :?

Thanks in advance.

Image
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Author:  drmini in aust [ Sun Mar 16, 2008 2:03 pm ]
Post subject: 
It's well knackered, the cause of your problems- toss it and buy a new one.
Also check for wear in the plunger it goes into, if grooved go find another. :wink:

Grease it good on assembly.
Author:  whiteski [ Sun Mar 16, 2008 2:42 pm ]
Post subject: 
Thanks Doc - appreciate your help.
Author:  simon k [ Sun Mar 16, 2008 5:17 pm ]
Post subject: 
that's probably close to what mine looks like....

does welding them up and grinding to a ball again work Kev?
Author:  drmini in aust [ Sun Mar 16, 2008 5:33 pm ]
Post subject: 
simon k wrote:
that's probably close to what mine looks like....

does welding them up and grinding to a ball again work Kev?

well you might be able to hardface it, but it's doubtful it will then last without the little arm bending as you will anneal it in the process.
I got one professionally TIG welded back together by Cigweld once, when the little arm bit broke right off, and it only survived 3 months.
Not worth the hassle IMO. New ones are not rare, or dear either.:wink:
Author:  1071 [ Sun Mar 16, 2008 9:57 pm ]
Post subject: 
Not that one would argue with god :) but....

I would suggest the damage is not tooo bad. However, check out the release bearing shuttle. It also wears and the combination wear patterns can do strange things.

I have had symptoms such as those described - but found the ball had broken off the clutch arm completely.

I think I would be looking elsewhere for the problem as I don't think a simple arm replacement will solve your woes.

Cheers, Ian
Author:  mickmini [ Mon Mar 17, 2008 3:43 am ]
Post subject:  Re: clutch lever arm wear
whiteski wrote:

My question

Is this wear on the clutch lever arm sufficient to cause the problem of severe clutch drag and trouble selecting gear or is it "within tolerances"? :?



Agree with Kev its goooooone, but here is why

http://www.minimania.com/web/SCatagory/CLUTCH/DisplayType/Technical%20Information/DisplayID/153/ArticleV.cfm
Author:  whiteski [ Mon Mar 17, 2008 9:04 am ]
Post subject: 
Hi Mick ... I appreciate the confirmation ... I read through that tip sheet on minimania ... its quite good and I think ... "only about 0.050'' of useful thrust bearing movement" ... puts things into perspective !
Author:  1071 [ Mon Mar 17, 2008 5:57 pm ]
Post subject: 
But sometimes you have to understand what you're reading.....

The wear MC describes is between the clutch pedal and the the master cylinder push rod.

The wear shown in your photo is easilly adjusted out using the clutch adjuster bolt. When it gets much worse people resort to bent lever arms. What's the inside of the release bearing shuttle look like?

I just wouldn't want you to be too disappointed when the new lever doesn't do much (you have checked the adjuster bolt haven't you?).

Cheers, Ian
Author:  drmini in aust [ Mon Mar 17, 2008 6:04 pm ]
Post subject: 
Often the plunger wears nearly as much as the ball does. The wear shown in your photo (if combined with a groove in the plunger) means the lever can run out of travel in the hole and will then jam in the plunger, before full movement is reached.
I had that problem once, and the ball wasn't worn as bad as yours (but it did bend the lever end).
Author:  1071 [ Mon Mar 17, 2008 6:41 pm ]
Post subject: 
This is true Kev, however, I've had a ball break off a lever - but the clutch still worked....

I still reckon if he races out and gets a new lever things won't be much better. The wear on the ball alone is not enough to cause the reported symptoms...

IMHO :)

Cheers, Ian
Author:  Morris 1100 [ Mon Mar 17, 2008 7:11 pm ]
Post subject: 
I don't like the way that he had problems so he bled the clutch and found air and when he bled it again later he got some more air.

I think this car has a couple of problems, some in the linkage and some in the hydraulics.
Author:  9YaTaH [ Mon Mar 17, 2008 8:22 pm ]
Post subject:  Gotta Agree
Morris 1100 wrote:
I don't like the way that he had problems so he bled the clutch and found air and when he bled it again later he got some more air.

I think this car has a couple of problems, some in the linkage and some in the hydraulics.


I'd say this car sucks :!: there is something letting air in somewheres :oops:
Author:  drmini in aust [ Mon Mar 17, 2008 8:51 pm ]
Post subject:  Re: Gotta Agree
9YaTaH wrote:
Morris 1100 wrote:
I don't like the way that he had problems so he bled the clutch and found air and when he bled it again later he got some more air.
I think this car has a couple of problems, some in the linkage and some in the hydraulics.


I'd say this car sucks :!: there is something letting air in somewheres :oops:

Exactly what Gafmo's car did last week. It was sucking air past the slave cylinder cup seal. Cylinder only 12 months old... there's Quality :P . A new 7/8" cup fixed it. :wink:
Author:  whiteski [ Tue Mar 18, 2008 7:32 am ]
Post subject: 
Will the clutch lever arm over extend because the ball is worn and if so will this damage the SC cup seal ?
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