will be done

 

Dual disks are on older 928's right? Mine is an S4, but I get your point. There are other threads where MC differences have been documented, and some say you have to modify any MC you buy. I didn't do this.

 

Back on the road!

I got the 3rd slave from Roger, and the ATE Blue Super Racing fluid. Put it all back together, flushed the lines and all the brake calipers and the clutch worked. My 14 yr old son and I took it out for a drive and I was feeling so good about it, I pulled over into a large parking lot and gave him his first driving lesson. (He turns 15 in 7 days) How many kids can say their first driving lesson was in a 5 speed 928 with a Lizard shifter? He did awesome, the car did awesome, and we made it home an hour or so later with the clutch till working!

So, the looking back, I'm fairly certain Valvoline Synthetic caused at least some of my issues. Maybe it was the mix with the old fluid, or maybe it swell seals on it's own, but it only takes a couple of months. I'd like to do some further testing when I get some time. Maybe soak 3 or 4 seals in various fluids then measure after a couple of months.

Thanks Roger for sending the new slave. I'll send slave #2 back, which may have been defective if it wasn't the fluid/swollen seals.

The RockAuto closeout slave ($26) also arrived. It is rebuilt and is stamped FTE, looks identical to Rogers new ones. I'll keep it as a spare and carry it around in the car like Herman does.

Hopefully this is fixed for the long term, I'm ready to focus on other parts of the car that need attention.

 

Great ending to the sage!

Also good feedback on the rockauto slaves - its worth 5-speed owners picking them up as spares, as that price is less than the rebuild kit

 

Well it lasted almost 2 months... clutch went to the floor today after sitting for about a week. Something really strange going on.

 

have you noticed that any of the springs have shattered in the any of the MC you have used?
Did you replace the flex hose?
Have you made sure the feed line to the MC is one continuous rise to the reservoir?
if this isnt done then the feed port may be supplying air to the system

 

Stan,

No broken springs the many times I've been into the MC.

I'll check the blue line to see if it's up hill to the reservoir, but I did replace it.

I did not replace the flex hose. Hard to tell for sure, but it looked like it might have been replaced before. I can't see any issues with it, but it's got that insulator layer, so hard to tell for sure. Wouldn't I see some leakage from this line if air was getting in?

 

the flex hose can really be a flex hose and start looking like a balloon once it heats up.

NOTE since this part hasnt been replaced with the rest of the system,
I would suggest to Contact Greg Brown and procure one of his clutch flex lines,
it will last the life of the car and is well worth the price of admission.

Note I am pretty sure your really sick of messing with the clutch hydraulics by now,
so you might be willing to pay almost anything to have a reliable working clutch

 

Stan,

I finally found some time to look at the car, and found that there was a high spot in the blue hose, so not 100% downhill from the reservoir. I don't really see how that could let air into the system, but I can see how air could be trapped there and eventually find it's way back down into the MC.

I shortened the blue hose by about 3" and bled the clutch and it's working fine again. I'm hoping that was it. If it makes it 3 months this time, I'd feel confident, but unfortunately Marble Falls is less than 2 months away. I really want to experience the Saturday drive in a 5 speed! I'll probably just chance it and take a small aluminum floor jack and jack stands with me just in case. Hell, a few years ago Donald made it all the way to Marble Falls with no clutch, so if he can do it...

Thanks for pointing me in the right direction.

 

It lasted almost one month this time and went to the floor today when I was about 10 miles from the house. I made it home in city traffic with no clutch. I had to start the car in 2nd when I hit a red light, which happened numerous times. Not fun but at least I didn't have to have it towed.

So it's not the blue hose, MC and Slave are new... I guess I'm ready to replace the rubber line, but don't really see how it could be causing the problem.

 

How's the routing?

I had a problem with my clutch line at one point overheating - the bracket it shares with a manifold bolt was twisted holding it very close to the exhaust manifold (RHD car tho' - I'm not sure whether LHD can be mis-routed?)

Does the clutch work again after the car's cooled down?

 

No, the clutch has not recovered. Every time this happens it has to be rebled to get it working again. Somehow air is getting into the system. The blue line was not downhill all the way, so I shortened it by about 3" thinking that was the issue as Stan pointed out. There are no fluid leaks.

 

try replacing the flex hose use Greg Browns part

 

sounds like the stock flex line might be ballooning and seeping in air... if i had to venture a guess. i am about to do a complete swap this week, MC, SC, new metal line, gregs hose, and blue hose....

 

wow, what a odyssey.

I got so lucky when I did mine. The entire clutch hydraulic system was out because of a flex line rupture when I bought her. I was apparently lucky enough to rebuild master and slave, replace the flex and blue hose and bench bleed. Worked the first time and ever since.

Think I will kiss the ground every time I drive her from here on out.

Hope you get it resolved soon Don!