They just want to see if we can take a joke............

FRANKIE

Zorg Guru (V)
American Zeds
The M44 Massive
Joined
Sep 2, 2013
Points
193
Location
Egg Harbor Township, New Jersey, USA
Model of Z
Z3
I had lost my clutch in the 1.9 several months ago and the car has just been sitting there in the drive. I was about a mile down the road when suddenly, I couldn't shift. The clutch disc wasn't slipping, I just couldn't get it out of gear. I turned the ignition off and allowed the compression to bring the car to a stop. Thankfully I was on a small road with no traffic. Once stopped, I was able to get out of gear without using the now useless clutch pedal. I put it in neutral and started the car. I couldn't get it into any gear. I stopped the engine and then I could get it into first gear. With no cars around, I started the car in first gear and made a U-turn and headed back to the house. I was able to shift without using the clutch. Anyone who's driven a truck for some time knows how to do this efficiently. When I got very close to the house, I put it into neutral and glided into the driveway. All I could think of was not being able to stop and hitting the ///M in the front of the driveway. I've been so tied up with things and then the winter, not being able to work inside on it, I had to let it sit. I figured it was either the clutch master cylinder or slave cylinder. The slave cylinder looked much easier to replace so I did that the day before yesterday. It was easy enough except that the hydraulic line coming down from the brake reservoir (they use the same reservoir), is attached to the slave cylinder using an 11 mm nut. This means you should use an 11 mm flair wrench to get it off. I've never even SEEN one. All the sets of flair wrenches have a 10 and 12, no 11. Two 13 mm bolts hold the slave cyl. in place next to the bell housing. I had to remove these, remove the slave cyl. and let it hang loose. In that position, I was able to get a vise grip on the 11 mm nut and channel lock pliers on the body of the hanging slave cly. and turn it off. It came loose before long. Replacing it with the new slave cyl, I bolted it back up and reverse bled the system from the bottom up. When testing the clutch, there was no difference indicating that the master clutch cylinder was the one that was bad. I'll start on that now and get back to you. When one goes, you're supposed to replace them both anyway. Teaches me a lesson for trying to take the lazy way out. Perhaps get some pics or a vid of the operation. Frankie
 

FRANKIE

Zorg Guru (V)
American Zeds
The M44 Massive
Joined
Sep 2, 2013
Points
193
Location
Egg Harbor Township, New Jersey, USA
Model of Z
Z3
I'm not sure what the actual name is but it is the access panel above the pedals. What a pain in the axx. They are screws that have a small cover to them that's the color of your interior. Well, after 20 years, these didn't pop off, you had to break them to get to the screw head beneath them. I'll bet the dealership will ask a pretty penny for each of them which I'll have to get if I don't want to look at the screwheads.
 
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Grumps

Always happy, apart from when I'm not 🤬
Supporter
British Zeds
Joined
Apr 27, 2014
Points
226
Location
Forest Town, Mansfield
Model of Z
Z4 e85 2.5i
Interesting read @FRANKIE. I'm going through the same thing with my daily driver. Put a Clutch slave on and hasn't cured the problem so ordered a clutch master which should arrive tomorrow. Hopefully this should see it right. If this doesn't solve it I'm at a loss as there's nothing else on the system other than the clutch itself. Had a couple of friends look at it and both say the clutch itself feels strong and the problem is definitely hydraulic.
 

FRANKIE

Zorg Guru (V)
American Zeds
The M44 Massive
Joined
Sep 2, 2013
Points
193
Location
Egg Harbor Township, New Jersey, USA
Model of Z
Z3
Interesting read @FRANKIE. I'm going through the same thing with my daily driver. Put a Clutch slave on and hasn't cured the problem so ordered a clutch master which should arrive tomorrow. Hopefully this should see it right. If this doesn't solve it I'm at a loss as there's nothing else on the system other than the clutch itself. Had a couple of friends look at it and both say the clutch itself feels strong and the problem is definitely hydraulic.
I know in the back of my mind that I'll always have age related problems with old stuck parts (on the CAR). I spent about 10 hours trying to get this clevis pin out. I thought I could get a c-clamp on it. When I tried, it wasn't deep enough so I went back to the store and bought a deep c-clamp. There wasn't enough room with all the wires to get it on the pedal shaft and be able to turn the screw part with all the wires. I tried tapping on it for another hour and it didn't budge. I was able to turn it gripping the end that holds the clevis pin. (I can't help think that that term "clevis pin" sounds like part of the female anatomy. The only thing that really kept me from losing my temper all this time was that I kept laughing to myself as I was thinking: "I can't wait to get my hands on this Clevis Pin.") At any rate, I came to the conclusion I just couldn't enough power on the end to this thing to punch it out. I started looking at the possibility of having to remove the entire pedal, which by the way seems to be made of plastic. Then the light bulb went off in my head and I thought of something that might work. A slide hammer. I had one in the basement. I got it and was able to set it on the end of the pin. I hit it the first time with no result. I set it up a second time and this time really nailed it and it pushed the end of the pin flush with the side of the pedal, moving it about 3/8 of an inch. I was elated! I didn't finish tapping it out all the was as it was getting dark and had to quit for the day. I was going to put the cover on the car because I thought it might rain. I went on the computer to see the weather forecast and they said there was the slight chance of an isolated sprinkle and by the morning, clear skies. Naturally, stupidly, I took their advice. We had a sever thunderstorm that poured BUCKETS!!!!. Well, at least it washed the pollen off the car. I took some vid with the slide hammer that I'll post later tonight.
It's better that it worked the way it did with your slave cylinder not being the problem as you would have been upset with yourself if, after replacing it, the master cylinder went bad a week later. At least you'll have replaced both of them and you'll have peace of mind. Let me know how you make out.
I'll post some vid later tonight. Frankie
 

Grumps

Always happy, apart from when I'm not 🤬
Supporter
British Zeds
Joined
Apr 27, 2014
Points
226
Location
Forest Town, Mansfield
Model of Z
Z4 e85 2.5i
I will @FRANKIE. Courier has just text me to say it's arriving tomorrow so I'll have it on over the weekend if not before.
 

FRANKIE

Zorg Guru (V)
American Zeds
The M44 Massive
Joined
Sep 2, 2013
Points
193
Location
Egg Harbor Township, New Jersey, USA
Model of Z
Z3
I will @FRANKIE. Courier has just text me to say it's arriving tomorrow so I'll have it on over the weekend if not before.
OMG!! Where do i begin? Seems like I've been working on this master clutch for days! I did a small video. In the video, I relate where I've used a slide hammer to budge the clevis pin. After removing the retainer clip, about 3/8 " of the clevis pin is exposed, part of which is where you attach the clevis pin. Looking towards the front of the car, it is on the left side of the pedal shaft. While this piece was protruding, I lined up a slide hammer onto this nipple and hit it to loosen is. You can see in the video that it is flush with the side of the pedal after doing this. I had hammered on this small nipple for hours and hours without moving it. I only was able to grip it and rotate it. Once the retainer clip was removed, it was supposed to slide out. Bu@@sh@@. I thought I'd use a c clamp with a socket to press it out allowing the pin to be pushed into the socket. Not enough room to turn the screw handle.
At the end of this video, I still hadn't removed the hydraulic fluid supply line from the master cylinder and hadn't removed the end of the cylinder from the slave cylinder line. In the U-tube video of the mechanic doing it, he pushes off a clip from the end of the master cylinder to release it from the slave cylinder line. I tried to do this for 2 hours. Finally I got out the dremel and cut off the clip. Still didn't come off. After I cut into the end of the master cylinder in 5 different places, it finally slid off. Almost another hour. Removing the fluid supply line from the top of the cylinder didn't work well. There's a tube coming from the supply hose that goes into a grommet on the top of the cylinder. This tube doesn't slide out of the grommet but pulls the entire grommet out of the top of the old master cylinder. This little tube is about an inch long. It is hell trying to get it out of the supply hose without damaging the hose. Once it was out, I pulled off the old grommet, removed the new grommet from the new cylinder, and attached it to the tube. I then inserted the new grommet back into the new master cylinder. To try and reinsert this back into the cylinder while it is up in place would have been impossible.
Grumpy, you must remember this: In the video of the mechanic doing the job, the car is probably on a lift where he can reach up into the car to work on it. Unless you have a lift, when you're working on it, the car is either at ground level or slightly raised on a jack. Working on this is extremely difficult as you are kneeling on the ground next to the car. I had to get a pillow to place on the edge of the car as you have to rest your body on this edge and it cuts into you. It's very difficult to get both hands on the job because of the position you're in. The positions you must hold your upper body in while reaching up above the pedals can only be held for a limited amount of time before you must rest for a few moments. You're constantly straining yourself trying to reach everything and there are many things you are forced to do using one hand and often to attain these positions where you are finally able to reach what you're working on, you can't position your head to look at it. Many times you are working blind. And I'm still not finished. If I had to rank this on a scale of difficulty from one to ten where one is the easiest, I'd tell you it was 100. Don't do it. If you have to work a month of overtime at work to pay to have it done, you would find that more acceptable. If you watch the second video of the mechanic doing it, you'll hear him say: "I can't wait till I'm finished this job!". And remember, he's working from a much easier position. I couldn't remember the last time I told someone not to do a repair. Sometimes they are tough but you can get it done. This one's a nightmare. There's no money you possess that you wouldn't give freely to have someone else do this job. Remember, its the position you have to work from that makes this job so agonizing. Frankie

Remember, at the end of this video, I still must attach the small tube coming out of the top of the master cylinder grommet to the brake cylinder reservoir hose, attach 2 bolts to hold the cylinder in place, attach the clevis pin and retainer clip, and attach the electrical switches plate for the clutch and brake. I just needed a bit more fun before the job's completed. Also, all the panels must be put back in place and I must order the small screw decorative caps. Also, bleed the system.................. Frankie

View: https://youtu.be/V7LYAyry0lA




And here's the mechanic doing it. It seems to be similar to my setup but perhaps a different year...............

View: https://youtu.be/7DlGdizfGIg
 
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Grumps

Always happy, apart from when I'm not 🤬
Supporter
British Zeds
Joined
Apr 27, 2014
Points
226
Location
Forest Town, Mansfield
Model of Z
Z4 e85 2.5i
Oh dear @FRANKIE sounds like your having a mare. Mines situated next to the brake master on the bulk head just under the bonnet. Two 10mm nuts and a pipe and it's off. Should take no longer than 15 minutes including bleeding the system.
 

FRANKIE

Zorg Guru (V)
American Zeds
The M44 Massive
Joined
Sep 2, 2013
Points
193
Location
Egg Harbor Township, New Jersey, USA
Model of Z
Z3
Oh dear @FRANKIE sounds like your having a mare. Mines situated next to the brake master on the bulk head just under the bonnet. Two 10mm nuts and a pipe and it's off. Should take no longer than 15 minutes including bleeding the system.
Go for it.

Check this out. Tried it myself after installing the slave cylinder and it works very well..............

View: https://youtu.be/wdf--suwqw0
 
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