[Darth Vadar]

Well, the new Sachs Clutch, Pressure Plate and DM Flywheel are all in (along with the other related required parts to do the job right!)



So it was only logical that all of the Hydraulics should be refreshed as well; no sense in doing the big "C" if the clutch hose bursts on turn 3 at Gingerman in a DE event! Or the Slave Cylinder starts peeing on the Dan Ryan going thru Chicago at rush hour!!! Well, you get the idea!



So, I strip out all of the old stuff, and start dropping in the new goodies (had to pull the Driver's Seat cause I'm too fat to squeeze in there and hook up the Master Cylinder Clevis otherwise!)



Of course, I put in the Master Cylinder, got it all hooked up, and then started to connect the Hose...Let me offer some advice... if you are going to do this job, connect (albeit loosely) the Hose to the front of the Master Cylinder BEFORE you put the Master Cylinder back in place!!! I spent no less than 45 minutes futzing with the fitting, trying to get it to line up with, and screw into the front of the Master Cylinder!!! WHEW!



So, if you're STUPID, like me, here's a couple of tips on how to do this the HARD way. Once you get the new hose fitting into position (sort of), use a 10mm (yes, I said TEN!) long open end wrench, positioned on the tubing and against the face of the Connector, to guide it into the hole at the front of the Master Cylinder, and to keep a gentle pressure on the Connector while you are attempting to turn it in with the required 12MM open end wrench, which is practically impossible to do because of the angle the tubing enters the mouth of the Master Cylinder. The Connector has to be EXACTLY straight going into the Master Cylinder, or you won't be able to catch a thread, or worse yet, you may cross thread the Connector!~!!



Once you are sure you have it "Square" with the face of the Master Cylinder, and are holding it ever so gently in position with the 10mm wrench, try using a long Punch with a small flat face, to begin turning the flats of the Connector into place. Just use the tip of the Punch to press and turn each flat, until you feel the threads begin to bite. Then, go ahead and gently use your 12mm open end wrench to cinch things up... and it WILL take you a while, as you will only be able to turn one half of a flat at a time!!! Patience here, plus a few well chosen curses, work well. I know some of you have probably purchased the "New" Clutch Hose, and are facing this dilemma as we speak! Slowly, slowly! Have Fun!



Underneath, I had good luck using a 19mm Tubing wrench (Crows Foot?) to hold the Hose fitting, while I connected up the Hard Line by hand, and then, again carefully tightened the Connector with the 12mm open end.



Treat the Hard Line very nicely, as spares must be either made locally or ordered from Germany!

Now to fill the Motive Power Bleeder and go at it! Hopefully, I won't have to do the Push, Hold, Release thing, as the better half doesn't take instructions well, and would probably kick a jack stand over while I was under the car!!! ;>((



Now, on to fitting the M030 Bars and new Bushings!!! Can't wait!

Partial Post: Please Login or Register to read the full post.

[flash]

strange you had so much trouble with the hose - i had no trouble at all with any of the 3 i've done (1 OEM, 2 stainless) - they all turned by hand quite easily and nicely until they were nearly seated and then i could get a wrench on them - yes, i had to flip the wrench back and forth, but that was really the only pain - the angle is deceiving, and perhaps you just couldn't see it - that happens

Partial Post: Please Login or Register to read the full post.

[Darth Vadar]

I think a combo of very tight space and extra large fingers conspired against me!



No way could I get two fingers on the Connector to start it into the Master Cylinder!



But, glad it's done and don't have to worry about it for another few thousand fun miles!



Oddly, the original hose looked almost new, and showed no sign of deterioration, but I guess they fail from the inside out...

Partial Post: Please Login or Register to read the full post.

[Cloud9...68]

Hmmm... Just placed my order for the master and slave cylinder, and I plan to order the SS hose and the lower suspension brace from RS Barn as soon as the clutch cylinders arrive (there was some question as to availabilty at Sunset). I hope my experience is more like Flash's than Darth's, but with my luck, probably no such luck... Flash, since you had so little trouble with your installs, any suggestions as to approach? i.e., is there a particular sequence you would recommend following? Thanks.

Partial Post: Please Login or Register to read the full post.

[flash]

yes - step by step instructions come with the new hose - if you have some issue along the way, contact pete or myself - we will be happy to work you through it



i do NOT recommend putting the hose on the master cylinder first - in fact, in the instructions i caution against doing that - with the stainless hose, clearance is indeed tight, but if you put the hose on first and then drop in in at anything but the perfect angle, too much side pressure on the line can easily crack it - the master does not need to be bench bled



it takes patience and it takes looking at it with angles in mind, or not looking at it at all, and going by feel - the job is also easier if you move stuff out of the way above the cylinder



not sure exactly what went on with darth's installation, but so far all of the ones that i've heard of have been pretty straight forward - while everyone notes the tightness of space, the only 2 where i have heard of problems coincidentally both tried putting the hose on the cylinder first - fittings can be tough - angles are very specific



if it's any comfort, i had a heck of a time doing the brake bias valve, brake fluid was everywhere, and 4 letter explitives were flying

Partial Post: Please Login or Register to read the full post.

[Darth Vadar]

"it takes patience and it takes looking at it with angles in mind, or not looking at it at all, and going by feel - the job is also easier if you move stuff out of the way above the cylinder"



I think Flash hit it on the head exactly... I could have disconnected some various bits and pieces that were above and around the Clutch Master Cylinder, but chose to "Dive Right In", as it were...



It also seemed that the initial length of steel tubing coming out of the CMC (on the new hose) was a bit too long, and rubbed against the sheet metal until it was finally seated properly in the CMC. This is probably what Flash is referring to as causing an issue if you attach it to the CMC first... since I never tried it that way, I can't say, but it sure would seem like it would be easier to set the whole line and CMC in place, with the line loose in the CMC, and then snug it down after the CMC was bolted down...



Well, it's over and done now...when you do yours, let us know how much fun you have!

Partial Post: Please Login or Register to read the full post.

[flash]

yup - exactly



i am now not surprised you had the issues, having left that stuff in the way - perhaps i should modify the install instructions to include that step

Partial Post: Please Login or Register to read the full post.