"GAZelle", clutch slave cylinder: device, adjustment

One of the components of the clutch mechanism is a hydraulic drive, which allows to act on the discs and the basket. The most important element of the clutch is the working cylinder. It provides the transmission of the effect on the mechanical components that are located in the basket. The "GAZelle" also has a working cylinder. Let's look at how the working cylinder of the GAZel clutch is arranged, on what principle this element works, what kind of breakdowns there are, how to service this part and change it.

What is a working cylinder?

This part represents the mechanism directing an excess of pressure from the main cylinder on a plug of deenergizing of coupling. As a result, the impact is transmitted to the checkpoint, and the driver can switch gears.

The working cylinder of the clutch "GAZel" (photo of it is in our article) on the device is no different from such cylinders for other models of cars. Structurally the part is quite simple. The cylinder is a metal casing with a special valve or air outlet. Inside the assembly there is a piston pusher with a spring.

Since the part works in a hydraulic system, it must be sealed. This is achieved due to the presence of sealing rings and a protective anther.

The working cylinder of the clutch "GAZel" is located under the cab, on the flywheel housing of the engine. The main and working cylinders are connected together by means of a steel tube and a rubber hose that withstands high pressure.

Operating principle

This detail of the clutch mechanism takes over the effort, which is transmitted through the pedal to the master cylinder. Then the pressure acts on other elements. This is a release bearing and a "fork". In the working cylinder of the clutch "GAZel", the device of which we examined, enters the tube from the hydraulic drive. There is a stock on the output. The latter one rests against the piston of the cylinder, and on the other hand it approaches the clutch fork.

Possible malfunctions

Coupling to "GAZel", despite all its advantages, still leaves much to be desired. For each owner of this car, the clutch mechanism brings a lot of inconvenience and becomes a headache. Due to the imperfect design of the unit, which does not have the special durability and reliability, it is necessary to change quite often the various components, to be engaged in repairs and adjustments. Owners are pleased only one thing - the cost of a new working cylinder clutch "GAZelle" is relatively low, and repairs are not particularly difficult. The element is dismantled, dismantled, and a defect is carried out. Then the worn out parts of the cylinder are changed and all are set back.

The fact that the repair of the clutch slave cylinder "GAZelle" is approaching will be indicated by the following signs. The malfunction may be indicated by a sharp drop 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 - the destruction of sealing elements or violation of the integrity of the hose. Eliminate this problem is simple enough. It is necessary to replace the damaged elements, and the tightness will be restored.

Also, the failure of the cylinder is indicated by failures or an excessively soft pedal stroke. This may indicate the presence of air in the main. The problem can be eliminated by pumping. In the process of inspecting the working cylinder and finding cracks (or places through which air can get into the pipeline), you can partly repair the part or replace the product with a new one. We will consider how to change the clutch slave cylinder to "GAZel".

If the clutch pedal gradually settles, there are problems with shifting gears to the gearbox, while there is no drop in the level of the working fluid in the tank, and adjustments to the pedal do not give anything, this indicates the failure of the return spring. The replacement of this problem will help.

On sale it is possible to find a repair kit of the working cylinder of clutch "GAZelle", which includes the main parts of the cylinder, subject to excessive wear and subject to regular replacement. These repair kits allow you to repair the unit yourself. The design of the part is simple, but it completely fails completely. But rubber sealing elements are made from frankly substandard rubber grades. This is reflected in the longevity of the work. But often to restore efficiency, it is sufficient to replace the cuffs of the "GAZel" clutch slave cylinder. Depending on the manufacturer, the set of seals can cost from 300 to 500 rubles.

Repair of cuffs

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

On the causes of cuff failure and how to eliminate them

Among the reasons may be leakage of working fluid due to depressurization, contamination in the hydraulic system, zazhpushunivanie, loss of operating characteristics of the working fluid. If such problems are observed and they are related to the brake fluid, then everything is solved by replacement and pumping.

More complex in terms of solutions are faults associated with breach of tightness. Often, depressurization occurs due to wear of the seals. First of all, you need to check if there is a leak.

Diagnosis of cuffs

If the brake fluid passes through the cuff of the working cylinder, then when it is examined on the parts, drops of liquid will be observed. The replacement of the damaged cuff can be done by yourself. For repair, you need a repair kit, pliers, and keys "13" and "17". You should also purchase a new brake fluid. Sometimes you may need a vise.

How do I replace the cuff?

So, you can repair the cuffs as follows. First, remove the working cylinder. To do this, it is necessary to apply pressure to the clutch fork with a certain force, and then, when the piston leaves, release the rod and remove it from the cylinder. Further, the key on the 17 loosens the nut holding the hose. The key on 13 is turned off by the bolts with which the cylinder is held on the crankcase of the gearbox. Then completely unscrew the cylinder from the hose. Then the dismantled clutch slave cylinder "GAZELI NEXT" is carefully inspected. To do this, it is cleaned of dirt, and then the construction is dismantled.

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

Then carefully study the cuffs themselves in the cylinder, inspect the internal parts. It should be examined as carefully as possible to see wear, shells, cracks. Often, one of the causes of malfunctions may be poor-quality parts. For example, a malfunction of the brake system may occur due to incorrectly tuned working mirror of the cylinder. Longitudinal grooves on the surface could cause wear of the cuff.

The replacement of the cuff begins with the preliminary treatment of the new part with brake fluid. Then the piston is installed into the cylinder, and the working edges are refueled. Reassemble in the reverse order. When the work is completed, the brake fluid is poured into the system and the clutch is pumped to remove air.

It should be taken into account that the new cuffs need time for grinding and running-in. During this time, minor leaks may occur. It is important to constantly monitor the level of brake fluid in the system. About cylinders for "GAZelle Next" it is necessary to say that they practically do not flow. This problem was solved. The manufacturer installs products of the firm "Saks".

The instruction on replacement of the working cylinder

Replacing the clutch slave cylinder "GAZel" is very simple. But beforehand, using a syringe, the hydraulic working fluid is pumped out.

Then, using the end head "for 10" unscrew the nuts holding the tank, and remove the hose. Next, disconnect the metal tube, which goes to the working and master cylinders. Then the end head "for 13" is turned off the nuts securing the cylinder from the gearbox. Using the key "on 17" remove the supply hose. It remains only to unscrew the nuts. After you can dismantle the part, and in its place to install a new one. At this, the replacement of the "GAZel" clutch slave cylinder is finished. It remains to collect everything in reverse order.

How to adjust the clutch?

If the car does not touch, then you need "GAZel" adjustment of the clutch slave cylinder. In this case, the clutch pedal travel is longer than required by the manufacturer.

The ruler measures the distance from the floor of the machine to the pedals and looks at the result. If it is higher than 14-16 cm, then adjust the bolt. The latter is under the hood (where the clutch element ends). The lock nut on the bolt is twisted, thereby achieving the necessary pedal travel. To increase the clearance, tighten the nut. And to reduce - unscrew.

Adjusting the pusher travel of the clutch fork

To do this, pull the spring from the fork with pliers. Then the spring is completely removed. Next, a ruler or a square measure the free stroke. A corner is placed so that it can rest against anything.

When the element is installed correctly, push the fork forward until it stops and fix it in this position. Next, remember the position of the square with respect to the fork. The last one is released and the free wheel is checked. If it is less than the passport rate, then the plug is regulated again.

First of all, one key is to hold the adjusting nut. The second key loosen the lock nut. Further, the pusher fixes the pusher from turning. Then, the lock nut is loosened and the correct fork free movement is achieved by rotating the adjusting nut. If all is correct, the pusher is again held in place by the tongs and tightened by the lock nut.

Bleed the working cylinder

Let's see how to pump the clutch slave cylinder onto the "GAZel". To do this, you need a hose, which can be tightly put on the outlet fitting. Also prepare a large syringe, the nozzle of which will fit the diameter of the hose. Also a key is needed to unscrew the air outlet valve.

What next?

For pumping, unscrew the cap of the expansion tank. Then the liquid is drawn into the syringe and the air is expelled from it. The hose is connected at one end to the valve, the second to the syringe. Unscrewing the valve with a key, pressurize the syringe and inject liquid. Further, without removing the hose, the valve is twisted so that air does not get into it. After that, you need to sit in the cab and create pressure in 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 how the air comes out of it. At the same time, its level in the surge tank will fall. We need to support it. Therefore, pour again the new brake fluid to the maximum mark. Then repeat the procedure again. Again, they sit down in the cockpit and pressurize the clutch system, pressing the pedal several times. Then the valve is unscrewed and looks at the liquid state. Bubbles should be less. 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).