General Fitment - Cape Parts Distributors
Contents
1. Your Undercarriage Specialist SERVICE BULLETIN DJ PARTS Subject Installation of Concentric Slave Cylinder CSC Issue Date DJ SB 022 C SC Apr 12 Specific Vehicle General Tools Parts Needed v DJ PARTS Brake Fluid v DJ PARTS Concenitnc Slave Cylinder The concentnc slave cylinder CSC is subjected to just as much natural wear asthe clutch or flywheel and should be replaced every time the clutch is changed There are a few important things to consider dunng installation in order to preserve the functionality and service life of the components 1 Whatto do v Do not depress the pedal several times in succession when bleeding depress just once and wait for hydraulic system to stabilize risk of over pressure inside CSC Y Do not use any lubncants or cleaning agents as they may damage the gaskets or the entire cylinder v Always maintain high level of cleanliness v Only use brake fluid approved by the car manufacturer v Clean old gaskets or remove tt if supplied with CSC and clean dust from the connection piece area v Clean the transmission input shaft and venfy not excessive wearon shaft seal swept area DJ PARTS ALAS S lt S Your Undercarriage Specialist SERVIC E BULLETIN Make sure the slave cylinder is installed flat against the transmission mounting surface Ensure the adaptor is engaged before finally tightening the fixing bolts on the CSC Install the slave cylinder fixing b2. ay be shown inconrect
3. itting DJPARTS 3 Your Undercarriage Specialist SERVIC E BULLETIN e In case of excessive axial and angular misalignment and shaft seal wear shaft rotation can generate mineral oil mist that could go in contact with intemal CSC pnmary seal with high volume change leading to leakage and low service life MANDATORY Bleeding Procedure A brake bleeding device should not be connected and switched on during manual bleeding If the clutch pedal is actuated with a brake bleeding device connected the concentric Slave cylinder can be over pressunzed An over pressunzed concentnc slave cylinder is no longer able to function and must be replaced Manual bleeding should be camed out using the following process a Depressclutch pedal Open bleed valve c Keep clutch pedal depressed until fluid appears Do not release Close bleed valve Release clutch pedal slowly i DO NOT DEPRESS THE CUICH PEDALIN SEVERAL TIMES IN quick SUCCESSIONS DURING E soit best DEPRESS SLOWLY ONCE ATA TIME e The clutch bleeding cycle must be repeated 20 to 25 times recommended to guarantee complete bleeding Top up the level of the fluid in the reservoir between the cycles The level of the fluid must not drop below the minimum mark on the reservoir dunng bleeding Problems with bleeding mainly occur in concentnc slave cylinders with bleed valves in the hydraulic line tis recommended only bleeding these systems manually ra
4. n ALWAYS USE DOT3 ORDOTA Abt FLUID AS RECOMMENDED BY SERVICE MANUAL DO NOTUSE MINERAL OIL v PREFER MANUAL BLEEDING FOR CSC THE HEA DISCARD USED OIL IN ACCORDANCE TO COUNTRY REGULATION Your Undercarriage Specialist SERVICE BULLETIN DJ PARTS 4 Brake Fluid Clutch System CSC cleanliness Contamination may cause sporadic leaks when dirt articles accumulate under the sealing lip and may also cause pemanent leaks when the lip seal swells ie Exclusively use brake fluid with at least DOT3 When open do not an the fluid longer than one year Change the fluid at planned interval Referto carowners wahai Drain the used fluid and rinse the line system with sufficiently new fluid Remove the compensating reservoir and clean it carefully The entire CSC system must be free from oil and grease Otherwise the lip seals swell Avoid grease on hands and oil on cleaning rags Make sure to remedy any leaks on engine and gearbox Make Sure that the gear bell housing is sufficiently sealed v Inorderto avoid contamination during epar work always close jambret and pipe connectors properly 3 Baal ee tan gq e Forfurther enquires consults our fnendly DJ PARTS service dealerin yourarea Note Whilst every precaution has been taken to ensure the accuracy of the information given on these tables DJ AUTO ASIA PACIAC PTE LID disclaim all liability for the consequences for any information which m
5. olts and tighten perthe vehicle manufacturer requirements Fill the reservoir with an approved DOT 3 or4 brake fluid NEVER bleed the CSC if the clutch and flywheel are not yet assembled reaction load to CSC Make sure the CSC is not inclined tilt during installation Failure may lead to damage at the lugs orreduced service life Referto angular misalignment Do not overtighten bleed screw Bleed screw torque for Plastic housing 3 to 5 Nm for Aluminium housing 15 to 20 Nm Angular misalignment 1 parallel offset 2 Angular offset v Excessive axial or angular or both CSC assembly enor reference to gear shaft lead to a reduced functional and service life of CSC reducing the life of the shaft seal gearbox input shaft seal v The root cause for excessive axial or angular or both CSC assembly enor is to be found in alignment errors between engine and shaft Possible cause of misalignment are e Centrng between engine and gearbox isnot correct deformation heavy dirt or wear e Other parts e g grounding straps trapped between engine and gearbox during installation e Flange bolts loose or not propery tightened e Close tolerance seeves or pins missing damaged e Gearboxinput shaft with no guidance as pilot bearing in the flywheel is absent or badly wom e Clutch bell housing warped because attaching bolts have not been evenly tightened ordeformed due to the effect of force such asdropping orstnking hard when f
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