"GAZelle", clutch slave cylinder: device, adjustment

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:41

One of the components of the clutch mechanism is a hydraulic drive that allows you to act on the discs and basket. The most important element of the clutch is the slave cylinder. It provides the transfer of impact to the mechanical components that are located in the basket. GAZelle vehicles also have a working cylinder. Let's look at how the GAZelle clutch slave cylinder works, on what principle this element works, what breakdowns occur, how to maintain this part and change it.

What is a slave cylinder?

This part is a mechanism that directs excess pressure from the master cylinder to the clutch release fork. As a result, an influence is transmitted to the checkpoint, and the driver can change gear.

Working cylinderThe GAZelle clutch (there is a photo of it in our article) is no different in design from such cylinders for other car models. Structurally, the detail is quite simple. The cylinder is a metal case with a special valve or fitting for air outlet. Inside the assembly is a piston pusher along with a spring.

Because the part works in a hydraulic system, it must be sealed. This is achieved due to the presence of o-rings and a protective boot.

The GAZelle clutch slave cylinder is located under the cab, on the engine flywheel housing. The master and slave cylinders are connected to each other with a steel tube and a rubber hose that can withstand high pressure.

Operation principle

This part of the clutch mechanism takes over the force that is transmitted through the pedal to the master cylinder. The pressure then acts on other elements. This is the release bearing and the "fork". The GAZelle clutch slave cylinder, the device of which we examined, includes a tube from a hydraulic drive. There is a stock at the exit. The latter rests on one side against the cylinder piston, and on the other hand approaches the clutch fork.

Possible malfunctions

The grip on the GAZelle, despite all its advantages, still leaves much to be desired. For every owner of this car, the clutch mechanism delivers a lot of inconvenience and becomes a headache. Due to the imperfect design of the unit, which is not very durable and reliable, it is necessary to change various components quite often, to deal withrepairs and adjustments. Owners are pleased with only one thing - the cost of a new GAZelle clutch slave cylinder is relatively low, and repairs are not particularly difficult. The element is dismantled, disassembled, troubleshooting is carried out. Then they change the worn parts of the cylinder and install everything back.

The following signs will tell you that the repair of the GAZelle clutch slave cylinder is approaching. A malfunction may be indicated by a sharp decrease in the level of liquids in the tank. In this case, under the car, in the place where the cylinder is located, there will be characteristic spots. This indicates leakage of the working fluid. Among the reasons are the destruction of the sealing elements or the violation of the integrity of the hose. Fixing this problem is quite simple. It is necessary to replace the damaged elements and the tightness will be restored.

Also, failure of the cylinder is indicated by failures or excessively soft pedal travel. This may indicate the presence of air in the line. You can fix this problem with the help of pumping. In the process of inspecting the working cylinder and finding cracks (or places through which air can enter the line), you can partially repair the part or replace the product with a new one. We will look at how to change the clutch slave cylinder on a GAZelle.

If the clutch pedal gradually sags, there are problems with shifting gears at the gearbox, while there is no drop in the level of the working fluid in the reservoir, and pedal adjustments do nothing, this indicates a failure of the return spring. Replacing it will help fix this problem.

On sale you can find a GAZelle clutch slave cylinder repair kit, which includes the main parts of the cylinder that are subject to excessive wear and must be replaced regularly. These repair kits allow you to repair the assembly yourself. The design of the part is simple, and it fails completely very rarely. But rubber sealing elements are made from frankly low-quality grades of rubber. This affects the durability of the work. But often, to restore working capacity, it is enough to replace the cuffs of the GAZelle clutch slave cylinder. Depending on the manufacturer, a set of seals can cost from 300 to 500 rubles.

Cuff repair

If at the moment of pressing the pedal it fails, and then remains at the floor level and does not rise back, then this indicates problems with the fluid pressure in the clutch hydraulic line. Using a machine with such malfunctions is undesirable, and even prohibited. If this happened on the way, then you can only get to the nearest service station with a lift or overpass.

About the causes of cuff failure and how to eliminate them

Among the reasons may be leakage of the working fluid due to depressurization, contamination in the hydraulic system, airing, loss of performance of the working fluid. If such problems are observed and they are associated with the brake fluid, then everything is solved by replacing and pumping.

More difficult in terms of solution are malfunctions associated with leakage. Often depressurizationdue to worn seals. First of all, you need to check if there is a leak.

Cuff diagnostics

If the brake fluid leaves through the cuff of the working cylinder, then when it is examined, drops of fluid will be observed on the part. Replacing a damaged cuff can be done by hand. For repairs, you will need a repair kit, pliers, as well as keys "for 13" and "for 17". You should also purchase new brake fluid. Sometimes a vise may be needed.

How to replace the cuff?

So, you can repair the cuffs as follows. First, the working cylinder is dismantled. To do this, it is necessary to press the clutch fork with a certain force, and then, when the piston leaves, release the rod and remove it from the cylinder. Next, use a 17 key to loosen the nut holding the hose. With a key of 13, the bolts that hold the cylinder on the gearbox housing are unscrewed. Then completely unscrew the cylinder from the hose. Next, the already dismantled GAZelle Next clutch slave cylinder is carefully inspected. To do this, it is cleaned of dirt, and then the structure is dismantled.

The cuff should be removed using round nose pliers. The retaining rings are removed from the groove, and then the piston is removed. If traces of oxidation or corrosion are observed on the surface of the piston, then a solvent is taken. After the return spring has been removed, it is necessary, using a clean rag, to wipe the working part of the cylinder (the so-called “mirror”).

Next carefully studycuffs themselves in the cylinder, inspect the internal parts. It should be inspected as carefully as possible to see wear, pitting, cracks. Often one of the causes of malfunctions can be poorly manufactured parts. For example, a malfunction of the brake system may occur due to an incorrectly honed cylinder working mirror. Longitudinal grooves on the surface could cause wear of the cuff.

Replacing the cuff begins with pre-treatment of the new part with brake fluid. Then the piston is installed in the cylinder, and the working edges are filled. Assembly is carried out in the reverse order. Upon completion of work, brake fluid is poured into the system and the clutch is pumped to remove air.

Be aware that new cuffs need time to grind in and break in. During this time, minor leaks are possible. It is important to constantly monitor the level of brake fluid in the system. It must be said about the cylinders for the GAZelle Next that they practically do not flow. This problem has been solved. The manufacturer installs Saks products.

Instructions for replacing the working cylinder

Replacing the GAZelle clutch slave cylinder is very simple. But first, with the help of a syringe, the hydraulic working fluid is pumped out.

Then, using the "10" socket, unscrew the nuts holding the tank and remove the hose. Next, disconnect the metal tube that goes to the working and master cylinders. Then endhead "13" unscrew the nuts of the cylinder with the gearbox. Using the "17" wrench, remove the inlet hose. It remains only to unscrew the nuts. After that, you can dismantle the part, and install a new one in its place. This completes the replacement of the GAZelle clutch slave cylinder. It remains to collect everything in reverse order.

How to adjust the clutch?

If the car does not move, then the GAZelle needs adjustment of the clutch slave cylinder. In this case, the clutch pedal travel is greater than required by the manufacturer's guidelines.

Measure the distance from the floor of the car to the pedals with a ruler and look at the result. If it is higher than 14-16 cm, then adjust with a bolt. The latter is under the hood (where the clutch element ends). The locknut on the bolt is tightened, thereby achieving the required pedal travel. Tighten the nut to increase the clearance. And to reduce - unscrew.

Clutch pusher travel adjustment

To do this, disconnect the release spring from the fork with pliers. Then the spring is completely removed. Next, a ruler or a square measure the free play. The square is placed so that it can rest against something.

When the element is installed correctly, press the fork forward until it stops and fix it in this position. Next, remember the position of the square relative to the fork. The latter is released and the free play is checked. If it is less than the passport norm, then the plug is adjusted again.

First of all, you need to hold the adjusting nut with one key. Loosen the locknut with the second wrench. Next, pincers fix the pusher from turning. Then the locknut is loosened and by turning the adjusting nut the correct free play of the fork is achieved. If everything is correct, the pusher is again held with pliers and the lock nut is tightened.

Bleeding the slave cylinder

Let's see how to pump the clutch slave cylinder on the GAZelle. To do this, you need a hose that can be tightly put on the outlet fitting. A large syringe is also prepared, the spout of which will fit the diameter of the hose. A wrench is also needed to unscrew the air release valve.

What's next?

For pumping unscrew the cap of the expansion tank. Next, liquid is drawn into the syringe and air is expelled from it. The hose is connected at one end to the valve, the other - to the syringe. Unscrewing the valve with a key, press on the syringe and inject liquid. Further, without removing the hose, the valve is twisted so that no air enters it. After that, you need to sit in the cab and pressurize the system. To do this, press the clutch pedal several times (but not less than five or six). Then we go under the hood and smoothly unscrew the valve.

If the hose is transparent, you will see airy fluid coming out of it. At the same time, its level in the expansion tank will fall. You need to support him. Therefore, fill again with new brake fluid to the maximum mark. Further procedurerepeat one more time. Again they sit in the cab and create pressure in the clutch system by pressing the pedal several times. Then the valve is unscrewed and look at the state of the liquid. There should be fewer bubbles. The procedure is repeated until the air is completely removed from the system (which is why it is so important to use a transparent hose).