Replacing the pneumatic booster with hydraulic clutch
We replace the CCGT if there are malfunctions:
- - jamming of the clutch actuator (with the clutch master cylinder and clutch mechanism in good working order);
- - increase in effort on the clutch pedal - no gain (with a pumped clutch hydraulic drive and serviceable master cylinder and clutch mechanism);
- - mechanical damage to the pneumatic booster housing, disrupting its normal operation
Removing the clutch booster
We prepare the car and release air from the consumer circuit
Remove the release spring 11 of the clutch release fork shaft lever
Disconnect the pneumatic pipeline 12 of the pneumatic clutch
Disconnect the hydraulic line 6 and drain the fluid from the clutch hydraulic
We unscrew the two bolts securing the pneumatic booster, release the pusher 15 from the lever, take it out and remove the pneumatic booster and the spring mounting plate
Installing the clutch booster
We insert the pusher 15 of the piston into the pneumatic booster and insert the second end into the hole of the lever of the shaft of the clutch fork
We combine the holes of the pneumatic booster with the holes of the clutch housing and fix it with two bolts. Bolt tightening torque 53.9-58.9 Nm (5.5-6.0 kgcm)
Connecting the hydraulic line 6
Connecting the pneumatic pipeline
Install the release spring 11 of the clutch release fork shaft lever
We start the engine and fill the pneumatic system with air, the pressure in the system must be at least 637 kPa (6.5 kgf / cm 2)
Pour fluid into the reservoir of the main cylinder through the upper hole with the protective cover folded down and bleed the hydraulic drive system
We visually check the tightness of the pipeline connections and, if necessary, eliminate the leakage
Adjust the free travel of the clutch fork lever
Repair of pneumatic booster with hydraulic clutch
Pneumatic booster disassembly
We install the pneumatic booster in a vise, clamping the rear housing 55 with sponges
Unscrew the bolts 4 with washers 3 and remove the air supply cover 5
Remove valve 7 of the booster assembly from the front housing of the pneumatic booster
We unscrew the bolts 2 and 23 with washers 1 and remove the front housing 25 as an assembly with the pneumatic piston 29
Remove the spring 27 of the membrane and the spring 46 of the pneumatic piston
Remove the diaphragm 17 of the pneumatic booster assembly
We unscrew from the rear case 55 of the amplifier the follower piston 33 with the case 31
We take out the thrust ring 45 and the clutch release piston 59 assembly from the rear case 55 of the amplifier and the seal case 43
Unscrew and remove bypass valve 48 of the rear housing assembly with cap 47
We unscrew the breather 49 securing the outlet cover, remove the cover and the seal of the air booster outlet
Remove the rear housing of the pneumatic booster from the vise
Remove the retaining ring 50 of the rear amplifier housing
Unscrew the nut 8 of the valve stem 15
Remove from valve stem 15 large washer 9, cone 10, small washer 11, valve seat 12, spring 13, tube 14, large washer 9, cone 10 and washer 11 small valve
Unlock at one point and unscrew the nut 18 of the reducer membrane
Remove the washer 19 of the membrane 20 and tabs 21 from the seat 22
Remove the sealing ring 35 from the body 31 of the follower piston
Remove the thrust ring 30 and the follower piston 33 assembly from the body 31 of the follower piston
Remove sealing ring 32 and cuff 34 from piston 33
Remove the washer 44 from the piston 59 of the clutch release, the piston seal housing 43 assembly with the sealing rings 41 and 42, the piston seal collar 40, the spring 38, the spacer sleeve 39, the thrust ring 62, the sleeve 61 and the collar 60
Remove from the front housing 25 the pneumatic piston 29 assembly and the sealing ring 26
Remove the cuff 28 from the pneumatic piston 29
We wash the parts of the pneumatic booster and blow them with compressed air and check the technical condition
Checking the details of the pneumatic booster
Traces of corrosion, scuffs, nicks on the working surface are not allowed on the rear housing rhnosti "A" case, diameter "A" more than 28.06 mm
Not allowed on the front body:
- - scuffs, dents, nicks of the working surface "A" of the body;
- - diameter "A" is more than 90.2 mm.
Not allowed on cuffs and o-rings:
- - wear and swelling of cuffs and sealing rings;
- - gaps and cracks in the working edges
On the outlet seal, signs of aging (cracks, breaks, loss of elasticity) are not allowed
Gusts, cracks, decrease in elasticity are not allowed on the membrane
Not allowed on the follower body:
- - nicks, scuffs, dents on the working surface "A";
Diameter "A" over 28.06 mm
Pneumatic booster assembly
We install the cuff 28 on the pneumatic piston 29 (Fig. 2)
Apply grease 158 to the piston groove 29
We install the sealing ring 26 and the pneumatic piston 29 assembly in the front housing 25
We install the sealing ring 42 in the seal housing 43
Note: hereinafter, before installing the sealing rings and cuffs, we lubricate them with NG-213 fluid
We put sealing rings 41 and 42 on the body 43
We install on the piston 59 of the clutch release the cuff 60, the spacer sleeve 61, the thrust ring 62, the thrust sleeve 37, the spacer spring 38, the spacer sleeve 39, the cuff 40, the piston seal housing 43 assembly with the sealing rings 41 and 42 and the washer 44 seal housings
We put on the follower piston 33 assembly in the housing 31
We install thrust ring 30 in the body 31 of the follower piston
We put on the body 31 the sealing ring 35
We install on the saddle 22 membrane tabs 21, one washer 19, two membranes 20, then another washer 19
Tighten the nut 18 of the membrane
Lock the nut 18 of the diaphragm
Lock the nut 18 by pushing the edge of the nut into the groove at one point
We put washer 11 small, cone 10, washer 9 large, tube 14 of the valve stem, washer 11 small, cone 10, washer 9 large on the stem 15 of the valve of the amplifier, tighten the nut 8
Installing the circlip 50 into the rear case 55 of the amplifier
Installing the rear case 55 in a vise
Screw in breather 49
Install and tighten the bypass valve 48 assembly with cap 47
We install the clutch release piston in the rear case 55 of the amplifier
Install thrust ring 45 into the assembled rear case 55 of the amplifier
We screw the follower piston 33 of the amplifier gearbox with housing 31 assembly into the rear housing 55
Install the spring 46 of the pneumatic piston
We install the spring 27 and the membrane 17 of the amplifier gearbox assembly in the front case 25, aligning the holes of the membrane with the holes of the front case of the amplifier
We install the front case 25 of the amplifier on the rear case 55 of the amplifier, screw in the bolts 2 and 23 of the fastening with spring washers 1
We install gaskets 6 and valve 7 of the amplifier assembly in the front housing 25 of the amplifier
Note: when installing the valve, use gaskets 6 to adjust the initial clearance (2 +0.5 mm) between the reducer valve and the diaphragm seat. There must be at least one gasket.
We install the air supply cover 5 on the front case 25 of the amplifier, aligning the holes, and screw in the fastening bolts 4 with spring washers 3
Remove the pneumatic booster assembly from the vise
Checking the pneumatic booster for tightness and performance
We check on the stand, made according to the scheme
The hydraulic system must be filled with brake fluid before testing. Fill with brake fluid and pump air using pump 10 of tank 11 and bypass valve 14 installed on the pneumatic booster
When pump 10 is running, it is necessary to unscrew the bypass valve by 0.5 turns for 3-4 seconds. In this case, the air in the hydraulic system will exit through the pipeline 12 into the tank 11. After all the air has escaped, close the bypass valve.
Simultaneously, with the help of pump 10 and tap 9, the control cylinder is filled with working fluid
The hydraulic system of the booster is checked for leaks using the control cylinder 7. In this case, the valve 15 of the pneumatic system must be closed (there must be no air in the pneumatic system)
During the test and the tightness of the hydraulic system, the stop q1 must be rigidly fixed. In this case, the load q must provide a pressure in the hydraulic system of the booster of 5.8 MPa (60 kgf / cm 2) according to the pressure gauge 6
During the test, the presence of brake fluid leaks through the seals in the amplifier elements is not allowed
The piston of the control cylinder 7 under the action of the load q must be motionless for one minute
The tightness of the pneumatic system is checked using compressed air tank 5. During the test, tank 5 must be under an air pressure of 687 kPa (7 kgf/cm 2) with tap 3 closed.
When tap 15 is open, air leakage through the amplifier gearbox is unacceptable. At the same time, the air pressure in the tank 5, controlled by the pressure gauge 4, should not decrease within one minute of the acceptance test
Checking for performance is carried out during the joint operation of all elements of the pneumatic booster.
In order to check the tests on stop q1, a dynamometer must be installed.
Load q must have three values A 1, A 2, A 3, providing pressure in the booster hydraulic system (P) 784, 1156 , 1569 kPa (8, 12 and 16 kgf/cm 2).
The air pressure supplied to the pneumatic system during testing must not fall below 589 kPa (6 kgf/cm 2).
When loading the control cylinder 7 with a load q according to the above three values, the force on the pusher rod must correspond to the graph
When holding at each point indicated on the graph for 15 seconds, the readings of pressure gauges 2, 6 of the dynamometer should not change
