Hey everyone,
I'd like some feedback on the hydraulic clutch set-up that I have installed in my 5.0 swapped Volvo 240.
-Modified clutch pedal to push instead of pull (mounted in the upper pivot in the pedal box, and lengthened to be at the correct position next to the brake pedal)
-Volvo 260 Master Cylinder (3/4" bore)
-CNC Clutch Slave Cylinder (7/8" bore, push style), mounted to the side of the T5 pushing against the clutch fork
The problem I'm seeing is that that I'm not getting much movement at the clutch fork. The clutch fork travels between 0.5 and 0.75 inches at the most... and from what I've gathered reading online it should be more around 1 1/4 inches.
Looking into what is causing this lack for clutch fork movement, my first thought was that it's not properly bled. But I even used a motive pressure bleeder until no more bubbles were coming out, and the clutch fork begins moving as soon as I move the pedal. Then I checked the total movement I am getting at the clutch master cylinder input rod. I measured this to be 3/4 inch. Is this clutch input rod travel normal? Seems too little to me. Also, this brings me to my other issue with the way the system is sized right now; the clutch pedal is waaayyy too light. I think I must have buggered the clutch pedal ratio and ratio between master and slave bores.
Now that I realize that the pedal travel is restricted to 3/4 inch, I did some calculations on what size master cylinder I should purchase to yield the 1 1/4 inch travel at the clutch fork.
Ratio between input and output travels = 1.25 / 0.75 = 1.6667
CNC Slave Bore = 0.875"
CNC Slave Area = pi*(0.875/2)^2 = 0.6013 inch^2
Area of needed master = 0.6013*1.6667 = 1.002 inch^2
1.002 = pi*r^2
r=SQRT(1.002/pi)=0.5358"
New Master Cylinder Bore = 0.5358" * 2 = 1.129" (1 1/8 inch)
Here is the wildwood master cylinder I am considering getting, it should give me enough clutch fork movement and a firmer clutch pedal:
http://www.wilwood.com/MasterCylinders/MasterCylinderProd.aspx?itemno=260-10376
Picture of the Slave Cylinder
Another Pic of the Slave Cylinder
Pic of the Clutch Pedal Box
Pic of the Master Cylinder
I'd like some feedback on the hydraulic clutch set-up that I have installed in my 5.0 swapped Volvo 240.
-Modified clutch pedal to push instead of pull (mounted in the upper pivot in the pedal box, and lengthened to be at the correct position next to the brake pedal)
-Volvo 260 Master Cylinder (3/4" bore)
-CNC Clutch Slave Cylinder (7/8" bore, push style), mounted to the side of the T5 pushing against the clutch fork
The problem I'm seeing is that that I'm not getting much movement at the clutch fork. The clutch fork travels between 0.5 and 0.75 inches at the most... and from what I've gathered reading online it should be more around 1 1/4 inches.
Looking into what is causing this lack for clutch fork movement, my first thought was that it's not properly bled. But I even used a motive pressure bleeder until no more bubbles were coming out, and the clutch fork begins moving as soon as I move the pedal. Then I checked the total movement I am getting at the clutch master cylinder input rod. I measured this to be 3/4 inch. Is this clutch input rod travel normal? Seems too little to me. Also, this brings me to my other issue with the way the system is sized right now; the clutch pedal is waaayyy too light. I think I must have buggered the clutch pedal ratio and ratio between master and slave bores.
Now that I realize that the pedal travel is restricted to 3/4 inch, I did some calculations on what size master cylinder I should purchase to yield the 1 1/4 inch travel at the clutch fork.
Ratio between input and output travels = 1.25 / 0.75 = 1.6667
CNC Slave Bore = 0.875"
CNC Slave Area = pi*(0.875/2)^2 = 0.6013 inch^2
Area of needed master = 0.6013*1.6667 = 1.002 inch^2
1.002 = pi*r^2
r=SQRT(1.002/pi)=0.5358"
New Master Cylinder Bore = 0.5358" * 2 = 1.129" (1 1/8 inch)
Here is the wildwood master cylinder I am considering getting, it should give me enough clutch fork movement and a firmer clutch pedal:
http://www.wilwood.com/MasterCylinders/MasterCylinderProd.aspx?itemno=260-10376
Picture of the Slave Cylinder
Another Pic of the Slave Cylinder
Pic of the Clutch Pedal Box
Pic of the Master Cylinder