Clutch master cylinder. "Gazelle": device and repair of the clutch master cylinder

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

To set the car in motion, it is necessary to transmit torque from the engine to the box. The clutch is responsible for this. It is this assembly that transmits the torque through certain gears to the wheels. The main function of the clutch is to temporarily disconnect the power unit from the gearbox. Also, the mechanism is responsible for the smooth start of the transmission links when the engine is started.

Device Feature

With the help of the clutch, it is possible to prevent a sudden change in load, which ensures a smooth start of the car from a standstill. The clutch also protects the entire transmission from inertial moment loads that result from a sharp deceleration of the crankshaft rotation on a running engine at the moment when the driver changes gear.

A hydraulic clutch system is installed on Gazelle cars. It has gained wide popularity on many models of modern cars. The design of the hydraulic mechanism is based on the clutch master cylinder. Gazelle "Business" is also equipped with it. The main task that the cylinder solves is the transmission of impulses from the pedal toworking element of the system. With the help of this node, the start of the machine is ensured. The mechanism also makes it possible to shift up and down gears.

Below we will consider the device of the clutch master cylinder. "Gazelle" is a commercial vehicle, so it requires periodic maintenance. What problems happen with the clutch, how to repair, maintain and, if necessary, change this unit? Let's talk about everything in order.

How the Gazelle's hydraulic drive works

It consists of a small number of parts and assemblies. So, in the system there is a reservoir of the clutch master cylinder. Gazelle has been equipped with it since 1995. The reservoir contains brake fluid, which works in the drive. The assembly also includes a master and working cylinder, tubes, hoses and nozzles. The system also uses a return spring.

The principle of operation of the hydraulic drive

If you do not go into details of how the clutch master cylinder works, the GAZelle works as follows. When the driver of the car presses the pedal, this force is transmitted through the rod to the main drive. Here it is perceived and passes through a network of tubes to the working cylinder. The latter, by means of a clutch fork and a release bearing, disconnects or connects the engine to the transmission.

Hydraulic drive device

Among the main nodes that are included in the design of the element, we can distinguish the pusher. With it, the pedal communicates with the mechanism. Also, this is the cylinder itself, the piston, the plugs and the return spring.

How is the clutch master cylinder? "Gazelle" is equipped with a node with two halves, which are separated by a special partition. The upper part is designed for the working fluid, which in the process comes from the tank. In the same place, in the upper part, a certain supply of liquid is stored. If the clutch and hydraulic drive are properly adjusted, then its level should be no less than three-quarters of the volume.

The work area is in the lower half. In the normal initial state, the piston of the cylinder is pressed against the wall by means of a spring, dividing the cylinder into two zones. There is a gap between the piston and the pusher. Due to it, the liquid enters the working part. When the driver presses the pedal, the push rod moves and closes the gap. Liquid can no longer flow from the upper zone to the lower one. The piston moves and the force is transferred from the driver's foot directly to the slave cylinder.

Due to the fact that the sizes of the piston and the outlet are different, the hole is enlarged. This is enough for the clutch to work. This design facilitates the effort that is placed on the pedal. This force is quite enough to disconnect the internal combustion engine from the box. When the pedal is released, a spring will act on the piston. Also, due to the pressure in the hydraulic system, the pedal will be able to return to its basic starting position. The pusher will also move to the same position. Due to this, the liquid will again freely penetrate into the lower container of the cylinder.

Whenclutch master cylinder needs repair

"Gazelle" may require repair if fluid leaks or air enters the system. Even though the design of the cylinder is simple, problems also occur with it. There are several faults. Details about each of them - further.

Liquid leak

Repair may be needed if a lack of working fluid is found. The reasons may be breaks or damage in the cuff of the cylinder, a violation of the tightness of the joints. In this case, it is recommended to make sure that the level in the expansion tank is sufficient. If there is little liquid, then it is added. Then periodically check the level during routine maintenance or technical inspection. Sometimes simply topping up the working fluid may not help. Then a thorough inspection is carried out, the place of leakage is identified and then tightness is ensured. In this case, you can not repair, but simply change the clutch master cylinder to the Gazelle.

Air in the system

Another typical malfunction is air in the system. Such a problem can lead to the complete inoperability of the node. The clutch will not be fully released, and the operation of the pedal will be accompanied by a characteristic crunch or vibration on the gearshift lever. Among the reasons why air enters the system and directly into the cylinders, one can single out various destruction of hoses, natural wear of parts. Do not exclude fluid leakage in places where sections of the hydraulic drive are connected to each other. How is the clutch master cylinder repaired in this case? "Gazelle" is placed on a flat surface, producedreplacement of damaged hoses with subsequent bleeding of the system.

Pumping fluid through the cylinder

There is also another malfunction - in this case, the cylinder can pump the working fluid through itself. The cause of the malfunction is the cuff, which is most likely damaged. Perhaps there is wear due to natural wear of the piston.

All of these faults can be repaired using a clutch master cylinder repair kit. "Gazelle" in this case, you can quickly return to working condition. The kit includes all the elements that often fail. The process of replacing the cuff and other parts is not particularly difficult for drivers of these cars.

If the first signs of cylinder failure are observed, the clutch system must be diagnosed and serviced. This will help avoid having to replace the entire cylinder.

Partial master cylinder overhaul with repair kit

With it, you can avoid the need to replace the entire assembly. The repair kit consists of the following parts:

• Protective cap.
• Retaining rings.
• Piston.
• Return spring.
• Gazelle clutch master cylinder seal.

To disassemble the cylinder completely, they are looking for a special plug on it. It needs to be unlocked. During assembly, a gasket must be installed under this plug.

Dismantling and Defetovka

The first step is to remove and disassemble the cylinder. Find himcan be in the left rear corner under the hood of the car.

Then, after the assembly is disassembled, all components are washed with brake fluid - do not use aggressive solvents for this. The cylinder is then inspected for burrs. Check the condition of the mirror and stock. If minor areas of corrosion or scuffing are noticeable, these defects can be eliminated with fine emery. But such damage may indicate a large gap between the cylinder and the piston.

Next, the worn components are replaced, which are provided in the repair kit. Before assembling the clutch master cylinder, the Gazelle must be put on the handbrake. Every part must be lubricated with brake fluid. A little grease is applied to the surface of the piston that will be in contact with the pusher. Next, the cylinder is assembled, installed in its place and pumped.

Replacing the clutch master cylinder

"Gazelle" requires this operation for the same reasons as in the previous case. These are leaks, normal wear and tear, improper operation of the clutch mechanism. As already noted, this cylinder is located on the left rear corner under the hood of the car.

Before the replacement itself is carried out, it is necessary to drain the brake fluid from the system. To do this, the hose is connected to a special fitting. The latter is located on the working cylinder.

Next, disconnect the clutch pedal from the cylinder. To conduct this operation, removethe part of the dashboard under the steering wheel. Then remove the fixing bracket, which can be found on the pedal and pull out the pin on the cylinder pusher.

When the fluid supply pipe from the master cylinder is disconnected, you can begin to unscrew the two nuts that hold the clutch master cylinder itself. "Gazelle-3302" continues to stand on the handbrake. After the nuts are unscrewed, the cylinder can be removed and a new one installed in its place. The installation process is carried out in reverse order. After assembling the system, it is imperative to bleed the drive.

How to remove air?

After any repairs to the hydraulic part of the clutch, the system must be bled. To do this, the liquid is poured into the tank literally to the brim, and the fitting must be unscrewed as far as it will go. Next, press the pedal several times. This is done so that the brake fluid gets into all the pipes. Then the pedal is fixed. Next, tighten the fitting and again squeeze the pedal several times, and then fix it. Next, a tube is put on the fitting. It is dipped into a bottle of liquid. The fitting is unscrewed to let the air out. All these steps must be repeated until there is no air left in the system at all.

If necessary, add fluid to the reservoir. It must be replaced in the clutch lines at least once every 2 years. Brake fluid is hygroscopic. This means that corrosion can form inside the system.

Pedal adjustment

After being repaired or replaced with a new clutch master cylinder, the Gazelle requires pedal adjustment. It's a simple process. For this operation, a ruler is needed, but the first step is to diagnose. If, when trying to start driving the car, the pedal sinks, various sounds are heard during the switching process, bumps and jerks are observed during movement, it is necessary to start the engine, release the clutch slowly and try to move off smoothly. If the car is in no hurry to move, then this indicates that the pedal is set incorrectly. Its course is more than it is determined by the norm. Next, using a ruler, measure the distance from the floor to the pedals. It should be no more than 14-16 cm. If it is higher, then the pedal must be adjusted. To do this, under the hood, you should find a bolt with a lock nut. It is located where the cable ends. The nut turns. This achieves the desired pedal travel. To increase the stroke, the nut must be tightened. If the stroke needs to be reduced, it is unscrewed. After adjustment, check the pedal again. Re-measure the distance with a ruler. The tuning continues until the desired result is achieved.