404 Clutch Hydraulics
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Thread: 404 Clutch Hydraulics

  1. #1
    Fellow Frogger! geodon's Avatar
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    Default 404 Clutch Hydraulics

    The connection between the master & slave cylinders is via a plastic pipe.

    I need to have the master re-sleeved in stainless steel.

    When the sleeve goes in they have to re-drill the port that feeds the pipe.

    The problem is the pipe won't budge. It is well & truly stuck in the master cylinder. I used a hot air gun to the point it started to distort so I stopped.

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    Any tips? The workshop said they could drill out the pipe & replace it with copper if needed.
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  2. #2
    1000+ Posts robmac's Avatar
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    Brute force and ignorance is the only way. The rubber seal over the plastic pipe has a tendency to jam up the assembly.

    You can't replace the line in copper because you need to have a flexible connection to engine.

    However, a front brake hose screws into the slave (imperial thread) and seals with a copper washer.

    At the other end at the master it's metric not imperial, however you can obtain banjo adaptor and bolt from brakequip to a imperial flare. And couple the hose end to the master. With an imperial 1/4 flare bundy line.

    I would salvage the pvc line if possible, it's a lot easier.

    404 Clutch Hydraulics-clutch-o2.jpg


    404 Clutch Hydraulics-clutch-01.jpg

    Edit: The nylon line needs new seal kits. Which consist of a rubber sleeve over the nylon line and a precision washer that goes between the securing nut and seal. And the nylon line needs inserts in both ends.

    The nuts only need to be snug. If the nut is bottoming something is wrong. And you will have repeat of your disassembly issues.
    Last edited by robmac; 20th September 2016 at 04:21 PM.

  3. #3
    Guru davemcbean's Avatar
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    Quote Originally Posted by robmac View Post

    You can't replace the line in copper because you need to have a flexible connection to engine.

    However, a front brake hose screws into the slave (imperial thread) and seals with a copper washer.

    At the other end at the master it's metric not imperial, however you can obtain banjo adaptor and bolt from brakequip to a imperial flare. And couple the hose end to the master. With an imperial 1/4 flare bundy line.

    I

    Or you can use the slave cylinder and flexible hose from a late 504 or a 505 and run the copper line from that to the master cylinder.
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  4. #4
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    Hi Geodon
    I replaced both master and slave with my sedan had the flywheel machined and a new clutch kit as the old clutch shuddered.
    When I put it all back together the clutch did not have enough throw to release fully so I used an old 404 trick in putting a ball bearing between the master cylinder and the actuator rod to take up slack in the system this did not fix the problem [my ute has an extension already welded to the actuator arm.]
    After lots of advise I had to pull the gearbox out remove the ball post the throw out arm pivots off replace the ball post and fit 2 thin washers between it and the bell housing it is also advisable to replace the throw out arm as they have been known to give way over time ,after this the slack was taken out of the system and machined flywheel allowed for and every thing worked perfectly.
    Lesson learnt the long way.

  5. #5
    1000+ Posts Wildebeest's Avatar
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    Geodon,
    One from the past.
    Clamp the plastic hose in a vice [wooden jaws] up close to the cylinder. Tap the cylinder with a soft head hammer pulling at the same time to release the hose.

    The copper pipe and flex hose sounds like a good mod too.

  6. #6
    1000+ Posts robmac's Avatar
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    Quote Originally Posted by Wildebeest View Post
    Geodon,
    One from the past.
    Clamp the plastic hose in a vice [wooden jaws] up close to the cylinder. Tap the cylinder with a soft head hammer pulling at the same time to release the hose.

    The copper pipe and flex hose sounds like a good mod too.
    A lazy (and wealthy) person may choose to have the entire plastic line assembly made up in braided hose.

  7. #7
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    Most of us meet only one of those criteria

    Guilty as charged

    Andrew
    Wildebeest likes this.

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