Xantia HDi hydraulic clutch

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flying clutchman
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Re: Xantia HDi hydraulic clutch

Post by flying clutchman » 13 Nov 2017, 11:19

Raising the suspension ain't gonna make the gap between the subframe and inner wing any bigger! The only way to increase the gap is undo the subframe.

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 13 Nov 2017, 18:04

Cheers Flying Clutchman

Shame as it would sure make it easier :oops:

Slowly slowly ....had to make another tool for the clutch as the force required to engage the snap ring onto the pressure plate was immense ... clutch slave cylinder engaged....foot pressure 'feels' good [-o<

Slowly going back together but getting colder ....I'm hoping to get the engine running again tomorrow and at least see if I can find the leaky pipe ....

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 14 Nov 2017, 19:48

clutch tools.JPG
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Clutch tools

Top - is a wall-tie bent to suit but couldn't grip enough to apply the force required.

Bottom - is a modified (engineered by angle grinder) swivel socket tool that done the job (just).

Middle - low pressure rubber return line.


Clutch tools (2).JPG

Rubber low pressure return pipe was the culprit, started her up today and found it, luckily it was near the join with the metal pipe so I was able to cut the damaged end off and re-bore the plastic pipe in situ with a drill bit. Looking closely at the pipe it was on the back of the pipe and I guess just disturbing the LHM reservoir was the final straw. If you can see on the 'tools' photo there is a split on the bend and another couple of cracks developing so all in all it was a good time for it to show up - not too much to remove for access and the car was at home anyway :wink:

The 2nd photo also shows up another potential leak point where a plastic tie has been used :!:

Tomorrow I'm hopping to get the driveshafts (bought a dust seal but not confident it's the right part) and wheels back on, test the clutch / gearbox operation then I just need my copper washer for the gearbox drain-plug before I refill the gearbox and test drive properly.

Thank you for your advice CitroJim / Flying Clutchman Kenny and the Admin at FrenchCarForum ...
Last edited by myglaren on 14 Nov 2017, 20:02, edited 1 time in total.
Reason: Second image rotated as per request.

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 14 Nov 2017, 20:04

Cheers myglaren

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CitroJim
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Re: Xantia HDi hydraulic clutch

Post by CitroJim » 15 Nov 2017, 05:37

Skull, excellent work so far... Well done!

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 17 Nov 2017, 12:20

old clutch.JPG
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old pressure plate.JPG
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2nd hand clutch/pressure plate anyone - 130,000 miles old
release bearing.JPG
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Release bearing seems a bit bent (could have been done during removal though)

More delays ...It seems she's enjoying her holiday. Taken me 3 weeks tomorrow :roll:

She was back together just waiting for some gearbox oil, got her down off the supports and started engine (speed and revs gauges pinged over and back to rest positions :?: never done that before 8-[ ). Then I thought I'd get her in normal height and just test the clutch on the driveway. When I moved the height lever the fuel filter spurted diesel everywhere. I had prior to striping down been trying to trace the leak which I thought was coming from the fuel/water drain off tap. Hindsight is a wonderful thing and I now think that the fuel filter is restricting flow and the extra flow to raise the suspension was too much for the seal to take, so I've ordered a new one. The fact that when I drained the filter housing and removed the (filthy and slightly distorted) filter there was still about an inch of fuel inside the housing which without the filter in was then free to drain off.
old fuel filter.JPG
Skull
Will check service history to see if I can date last change .... but looks like the original #-o

She is due a service post MoT and again I've been lucky that this has occurred at home (although the block paving is in a right state)

To be continued ...

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CitroJim
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Re: Xantia HDi hydraulic clutch

Post by CitroJim » 17 Nov 2017, 19:10

Skull, excellent work so far... Yours certainly had failed in the classic way...

You should soon have a set of stickers to decorate the car in the next day or so. I popped your order in the post a couple of days ago...

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 17 Nov 2017, 19:15

Many Thanks CitroJim :-D

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 21 Nov 2017, 15:39

Fuel filter fitted and sorted (last record of a change was 56K so that one pictured might have done 75K :shock: )

That enabled me to raise the suspension, support chassis on a level and get back under to fill the gearbox with fresh oil (very slow process in November temperatures, I was tempted to wack it in the microwave to warm it up). Done some minor jobs in between funnel fills.

All torqued up and a short road test and everything seems OK clutch lovely and light although gears seem less smooth to engage - maybe I've forgotten how to drive, hopefully settle down. Luckily I haven't had the trouble of having to bleed the clutch :roll: .

Just those stickers to fix (Cheers Jim) and tidy the tools away / sort garage out :oops:

With the exception of tools purchased It's cost me under £150 - just as well my hourly labour rate is cheap :wink:

Oil and Filter change next week and then look at sorting some of the MoT advisories. (Sticky nsf caliper and pads and osf suspension arm/bushes)

Cheers guys :-D

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Re: Xantia HDi hydraulic clutch

Post by lexi » 21 Nov 2017, 15:59

That is some nice work done in that little cold snap before the real weather comes on us. A great result for £150 too.
That filter man!

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CitroJim
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Re: Xantia HDi hydraulic clutch

Post by CitroJim » 21 Nov 2017, 17:00

Well done Skull =D> :-D A real cracking job!

For future reference, I always refill the gearbox via the reversing light switch hole ;) My method is to measure what comes out and measure back in an equivalent amount of new oil...

I use a funnel with a long translucent plastic extension tube on it...

I agree it's a tedious process in the cold and no harm in warming it up first. I'd not use a microwave, just drop the oil containers in a bowl of very hot water...

You are now a Xantia guru ;)

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 21 Nov 2017, 17:24

Same method Jim funnel and long tube ....just a different hole :roll:

Is there a guru badge :rofl2:

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Skull
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Re: Xantia HDi hydraulic clutch

Post by Skull » 21 Nov 2017, 17:36

lexi wrote:
21 Nov 2017, 15:59
That filter man!


I know :oops:

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CitroJim
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Re: Xantia HDi hydraulic clutch

Post by CitroJim » 21 Nov 2017, 17:56

Skull wrote:
21 Nov 2017, 17:24
Is there a guru badge :rofl2:


No, but there should be ;)

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Re: Xantia HDi hydraulic clutch

Post by Rhothgar » 28 Nov 2017, 19:00

It's a good job you're a long way from me, Skull! You could become our resident expert...

How come it cost £150? That sounds steep. I was hoping to get a clutch kit for around £90-£100.