Aargh! What have I done (CSR260 content)

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David Brown
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Aargh! What have I done (CSR260 content)

Many of you may recall that I've had a failed propshaft which, in the course of diagnosing, I've had the engine and gearbox out. Now got the shaft back and everything Re-assembled, Re-connected and fluids in. Just clutch bleed and re-connect the battery before restarting and going for the first run for 6 weeks. B****r, the clutch won't bleed and find fluid draining from the bellhousing/block joint. Obviously forgotten or damaged something and will have to remove the engine and gearbox to fix. The slave cylinder sits behind the dry sump oil reservoir plate in the bellhousing which I didn't disturb. Also I would have thought any leak there would have run into the dry sump reservoir. 
What could I have missed? Any suggestions gratefully received. 

Blue7
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Regrettably I don't have any practical suggestions but can you elaborate on "clutch won't bleed"?  I assume there must be a bleed nipple somewhere on the exterior of the bell housing and you are loosening the nipple, then depressing the clutch pedal but instead of fluid emerging from the nipple it is dripping from the bell housing joint?  I did find a couple of links that may be of some use

https://www.caterham7diaries.com/post/clutch-bleeding-wrong-assumption-over-the-nipple

https://www.lotus7.club/forum/techtalk/bleeding-clutch-urgent

David Brown
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Hi Blue, thanks again for your helpful posting. There is a bleed nipple on the outside of the bellhousing, not quite the same as the one on your first link but similar. When I tried to bleed the fluid just disappeared before I got rid of bubbles then discovered the fluid pouring out of the joint between the bellhousing and block. Having subsequently spoken to Mick Attree, who apparently was a consultant on the CSR introduction, I may have damaged the seal on the clutch actuator when pushing on the clutch pedal to separate the bellhousing from the engine. Apparently our cars are fitted with a Concentric Slave Cylinder which I've never seen before but your second posting shows one and was a great help. That installation is not the same as ours as it hasn't got the oil tank for the dry sump but am sure it will be much the same as regards clutch actuation. A spare seal is available so hopefully that is what I require. I've now got the engine/gearbox out again (quicker this time) but not yet tried to separate the two. Requiring to regain my strength, enthusiasm and a Macallan or two.

David Brown
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Blue7
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Ok that does sound like a damaged seal.  Likewise, I have never seen a clutch slave cylinder like that before now, what a hassle having to remove the engine just to replace a slave cylinder seal.  I think I might be tempted to replace the whole slave cylinder unit just to be on the safe side and avoid any possibility of having to remove the engine again if another part of the unit has been damaged.  However, I can't find them in the CC store, they have a similar unit for sadev 620R but at a whacking cost of £365.  In all the years I replaced brake cylinder seals they never lasted more than a year or so and new brake piston units were always the best option.  I wonder if there is a way to check that the slave cylinder actually operates without leaks "before" you reassemble engine & gearbox?  

Good luck and I hope your loved one keeps to well supplied with Macallan ... I know your daughter won't because she was stingy with us when we visited the Distillery last year Biggrin

David Brown
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For information for anyone else facing this issue, attached is a photo of the actuator fitted to  my CSR

David Brown
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For information for anyone else facing this issue, attached is a photo of the actuator fitted to  my CSR

Croc
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I pulled my CSR with dry sump apart last month and replaced the concentric seal which had failed.  The concentric slave had no wear on it at all - neither had the clutch.  Only the seal was perished.  I had the pieces to replace the entire slave but no need. I think we have to view the seal as a consumable anytime we pull an engine and just replace as a precautionary measure

The inner slave piston does not seem to be on Caterham parts website but the outer slave piston housing is:

https://caterhamparts.co.uk/clutch-parts/5099-housing-clutch-release-bearing-csr-dry-sump.html

Mine has to come out again this month.  I have a small oil leak from the bellhousing where the blanking plate covers the dry sump tank - not bad but enough.  I only disturbed the blanking plate as I was curious was to what was inside - my fault!  

 

Mike

David Brown
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Have the seal on order. Unfortunately not sure that the slave cylinder can be tested before Re-assembly. 

David Brown
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Mike, how did you replace the seal? Push it out with an air hose?

Croc
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Hi David,

I responded to your Blatmail but for the benefit of anyone following along - I used an air hose to get the inner "piston" to surface then used a puller tool to ease it out completely.  

Cheers

mike

Mike