Clutch master cylinder

[Kitcat]

This unit is dying in my '03 Zetec powered Caterham S3 with the 6 sp. Caterham transmission. As soon as the unit gets hot, shifting becomes nearly impossible.

 

Any ideas as to a suitable replacement? Can this be purchased at AutoZone, or is it a bespoke Caterham part? Thots, suggestions, solutions?

[scannon]

Have you tried flushing and bleeding the system?

 

I believe the clutch master cylinder on my '04 Caterham is a standard Girling unit. Take it to a foreign car parts store and they can most likely match it for you or sell you a rebuild kit which is much cheaper.

 

http://www.girlingauto.com/en/Products/Master-Cylinders/

[James A]

If it's a Girling master cylinder it is rebuildable here are both replacement units and rebuild kits: https://www.pegasusautoracing.com/group.asp?GroupID=MCGIRLING

Also, Wilwood makes a direct replacement for the Girling unit here: http://www.a1racing.com/wil260-2636.aspx?gclid=CJCZiaThlMYCFQiQaQod8BcAjQ

[coffee break]

I think fresh fluid would do it. A good flush would clear any moisture bearing fluid out. Is the slave easy to access?

[Kitcat]

Thx guys. There have been 3-4 flushes, each one is only good for a few laps. We may have a replacement already, I will know for sure tomorrow.

[MichaelD]

Does the six spd use the same one as the five spd?

[Kitcat]

Dunno MD. As you will recall, when I had shifting problems at last year's NJMP se7ens gathering, you did a field service and replaced/replenished the clutch fluid. That got me thru the rest of the event, tho it would always start to get progressively harder to shift as the session wore on. Until now, I have thought I was just not managing the 6sp properly, having used a 5 sp for so long.

[yellowss7]

I'm going to hazard a guess that the Master and slave cylinders are the same for the 5 and 6 speeds. Now get er done!!! :willy_nilly: Tom

[MichaelD]

The slave cyl is about $75 and resides in the bell housing. If that is going bad you need to pull the motor or remove the drive shaft to pull the t9 and to replace. Master cyl is about $36.

Hope you get it fixed before the 3rd.

[Kitcat]

Thx MD. The new clutch master cylinder fixed part, not all, of the shifting issue. So a new clutch, pressure plate and slave cylinder are on their way to Cincy and will hopefully be installed by end of this week. Cant imagine how nice it will be to able to shift at will:). Getting too close for comfort to the NJMP event tho.

[MichaelD]

Mike,

 

Once you have the engine/trany out is the any way the syncros can be checked? On thT9 there are things called Baulk? Rings. Don't ask me what they do. All I know is that the one for third to fourth can go bad frequently.

[Kitcat]

MD:

I will ask my mechanic to eye-ball it but the symptoms dont fit worn synchos.

Instead, with the new master cylinder, if shifts as smooth as butter. Then, it won't shift at all, no gears are available. Working theory is something has broken and is gumming things up intermittently (pressure plate spring maybe?). I will know soon.

[MichaelD]

Mike,

 

I did not ask at the track. Is it fixed and what was the cause?

[Kitcat]

It is fixed. The clutch pressure plate was in the process of separating from the flywheel. Various broken parts were floating around and gumming up the works. A new pressure plate, clutch, throwout bearing and slave cylinder were installed. As I am sure you know, that requires removal of the engine. See the thread with the "exploding clutch" heading for a discussion of what might have happened, but didn't.