Re: Clutch Pedal Breakage, 200TQ

[four.rings@MCIONE.com]

"Scott Mo." <scottmo@teleport.com> wrote:
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A couple of weeks ago the clutch pedal snapped on my '89 200TQ with
about 110k miles. It broke up near the top of the pedal at the short arm
that actuates the clutch master cylinder rod. After removing the pedal I
noticed the plastic bushing that locates the pivot on the clutch pedal
was also cracked. another list member commented that he had replaced 2
of these pedals on his 200TQ.
>>>>>>>>>>>>>>>>>>>
Yep, that was I.

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Another local list member pointed out how it is important to get the
clutch master cylinder rod adjusted correctly so the piston doesn't
bottom out in the bore of the master cylinder. If it does bottom out,
you will be levering against the small arm at the top of the clutch
pedal until the clutch pedal stop hits the firewall. It helps to remove
the carpet behind the pedal and check for full travel of the pedal.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
In my case both pedals snapped in the very beginning of travel, so I
couldn't attribute it to this cause.
I do attribute it to the MC piston jamming in the bore. I rebuilt it
once when it first started leaking and in the process noticed how pitted
the walls were.
Then the pedal broke. I thought it was just a grainy/fatigued casting in
the Al pedal and replaced it. It broke less than a year later in exactly
the same spot. This time I replaced the MC all together. No problems so
far.
As much as I advocate rebuilding anything hydraulic on the car, in this
case I'll make an exception: if I just replaced the MC it would've been
only $64 (new MC). The way I did it it was $16 (repair seal kit), $180
(two clutch pedals), and $64 (new MC). $260 total plus I had to drive
the car home without the clutch pedal on two occasions - not fun!

<<<<<<<<<<<<<<<<<<<<<<<<<<<
While I was down there monkeying around, I went ahead and replaced the
clutch master cylinder and the slave cylinder on the transmission. The
later 200's use a different clutch master cylinder and slave cylinder.
The master has relocated the fluid inlet so it does not interfere with
the mounting allen bolt. This may be the replacement master cylinder for
the earlier 5000TQ. 
>>>>>>>>>>>>>>>>>>>>>>>>>>>
I installed the MC from an '92 100. It was Fe (mine was Al) and had a
different feed spout, but fit perfectly well. The p/n was goofy too,
something like A0...... something, not the familiar 443/441.... type-44
nomenclature.

-- 
Igor Kessel
'89 200TQ -- 18psi (TAP)
'98 A4TQ -- nothing to declare
Philadelphia, PA
USA