Why's my NEW clutch master leaking? *PICS*
 

Hey fellas,

Having a little four letter word moment here during the restoration and wondered if some of you might be able to help me out. I've got the whole clutch system hooked up, hydraulics, pedal and everything. The pedal feels really nice and smooth except for some reason my BRAND NEW clutch master cylinder has started leaking. It is leaking between the reservoir and the actual cylinder. I bought it off of e-bay, and it is an original mazda part. I don't know what the problem with it is.

After putting it all together I adjusted the clutch pedal to what I thought felt satisfactory. It had quite a bit of freeplay initially, which I wasn't happy with. It has been so long since I've driven a manual tranny car, so I used my dad's new ford ranger as a guideline for what the pedal should feel like. I must say that the old mazda clutch system feels just as good as the one on the ranger I was comparing it too. Except it is leaking for some reason. Did I over adjust the pedal somehow and cause too much pressure in the lines?

I have also included some pictures of the clutch slave because it looks like the pushrod from the slave isn't going straight into the clutch fork. I don't know if that would cause problems or not. I also may have the push rod in backwards. One end had a stepped up bulb on the end, and the other was the same diameter as the rest of the rod. I installed it so that the larger portion of the pushrod is going into the clutch fork. It made sense to me to do it that way, but I may be wrong.

I'm at a loss right now of what to do. Were these things just pieces of crap from the factory or what? If there is anything that you can think of that would make my clutch master leak please let me know! :D

http://www.evingtons.com/glazedham42/clutchmaster.jpg

http://www.evingtons.com/glazedham42/slave1.jpg

http://www.evingtons.com/glazedham42/slave2.jpg

I just bought a brand new one also, and its has the same problem. I think its just lose or something???

Better put down a rag before it ruins your beautiful paint.

I'll let you know how I do when i get to it whenever it stops raining over here in LA.


-Ryan

*BUMP*

Still looking for some help and suggestions on this. Should I just get a new one from Autozone or what? I usually trust the Mazda replacement parts, but I guess there's no telling how old this thing really is. Is there a chance that it has been sitting around in a box since 1985? Should I buy another from somewhere else??

From what is on your post, you said that you put the push rod in backwards.. well that could make the system off, the side that is wider is there to stop the rod from poping out too far. It shouldnt come apart. When I received mine, it was one peice that wouldnt come apart ( the push rod cylinder to the clutch fork) But it doesnt come all the way out.. also make sure that there are no bubbles or air pockets in your system. No leaks in your hoses, and also make sure the hoses are tight.. I've had that problem on my truck before, but it was just an air bubble in the system that made it leak for me.. Hope I helped PM me for more if needed.

The only reason I can see for a leak in that location is if the resevior is cracked right there. If this is the case, you might be able to epoxy it from the inside to fix it. On the slave cylinder, the plunger will be angled slightly. If it was installed incorrectly, you should know it.

installing the pushrod backwards will not make it leak around the resevoir it has to be cracked or the rubber has to be leaking.

My first thought was that the rubber seal was bad also, however the resevoir could be cracked also causing the problem.

I think if you put the pushrod in backwards your would feel nothing in your clutch pedal so you must have it in right. And for that reservoir leak, the bottom just seals on there. Your must as others have said have a small crack, potentially during installation or and old mazda part not sealing correctly. I doubt you want to pull it out and bleed it all over again but you might just have to. Don't you hate doing shit twice, plus brake fluid is the devil, i hate having that shit on your hands. ISH!!!!!!!!!!!

Bump

Still looking for suggestions on this... should I just replace the thing?

Yes.

Look for a brand called "Tokico" It comes in a yellow box with black text on teh outside. I've put their cylinders in my RX-7 and in my truck. Quality stuff... OE Quality, right down to the same lettering and shape on the cap.

Hmmm... where can I get something like that? Napa, advance, autozone? My only concern is that the brand new one I put in was a mazda factory part. Do you think it's been sitting around since 1985, and is too old? Maybe the rubber seals are shot?

Wilwood units darn near bolt right in and are very nice and not that expensive.

Later
Randy

The part could have certainly been sitting on a shelf for nearly that long. The plastic resevoir and the rubber seal will dry out in time with no use. I would recommend buying a new one and no matter where you get its prolly gonna be a part thats been sitting on a shelf for many years.

You can get the Tokico clutch cylinder at http://www.nopionline.com. They are cheep to boot ($25 for the clutch master cylinder). Just stay away from the ricer stuff. :p:

Kent

What about the chance of me sealing around the reservoir with some silicone or something? Would this be a total waste of time? It is barely leaking through. I'm wondering if some silicone or jb weld would solve the problem....

Jamie

The tokico master cylinders on NOPI say that they are for the fuel injection models only, ie GSL-SE's. Will they still work on my 85 GS??

I guess it won't work then. I checked the Mazda microfiche and it does list different part numbers between the SE and non-SE models, although I am not sure of the actual differences. Good luck on it though. I don't think that I would use silicone or anything as brake fluid is pretty nasty stuff and I don't think it would hold up good. I have a reservoir on a clutch cylinder that I am not using (used). I am not sure of the condition of the seals, but you are welcome to have it if you want it.