I'm new to MBs and need to get a little guidance: I have an '83 manual 240D that I lost the clutch on. I believe it's the slave cylinder since I see no leakage around the master. I would like to get some information on replacing/rebuilding the slave before I tear into it. Haven't been able to find anything on replacement - does anyone know of a site that would provide some indication of the process? Is this such a simple job that no one has bothered posting on it? Also, is there any accepted wisdom on replacing or rebuilding?

Many thanks,
dt

I had to replace mine (201) last year. I had been experiencing a low pedal and clutch drag. I found the pushrod was worn about 1/8" at the contact point with the clutch fork. There was no external leakage or internal corrosion. I flush the fluid every two years.

The Haynes 190 manual was a good guide, and I think they make one for the 123. Access to the hydraulic line is very tight and required a wobbly extension with a crow foot tubing wrench of proper size. I think it was 12 mm, but can't remember for sure. I accessed the two mounting bolts (10 mm hex IIRC ) from behind with a couple of socket extensions. That's all there is to remove - the B-nut for the hydraulic line and the two mount bolts. Once I figured out the correct tools to get a bite on the nut and bolts it was quick and easy.

Another key is bleeding. Per the Haynes manual, I bled from the "bottom" up by connecting the RF caliper bleed valve to the slave bleed valve, which was open about a half turn. You then "bleed the brake", which forces fluid into the clutch slave cylinder and forces the air up and out to the reservoir. I did the clutch bleed after flushing the brakes, so it was fresh fluid. An empty clutch slave is almost impossible to fill/bleed by conventional bleeding at the clutch slave that you use for the bienniel fluid change.

After looking around for rebuild kits - with not too much luck - I bought a brand new slave from Fastlane. It was a Teves - only about forty bucks - and the cylinder has the MB casting number - same as the original.

Duke

Hi Duke,
Many thanks for the advice. I'll see if I can find the appropriate info in the Haynes manual and we'll see where we go from there.
DT

Lack of fluid leakage at the clutch master cylinder is no guarantee it is not faulty. It really depends upon the symptoms you are experiencing. Ongoing problems with the clutch in my 190E over a period of time, which eventually resulted in the clutch pedal going to the floor and staying there, were fixed with the replacement of the master cylinder.

__________________
107.023: 350SLC, 3-speed auto, icon gold, parchment MBtex (sold 2012 after 29 years ownership).
107.026: 500SLC, 4-speed auto, thistle green, green velour.
124.090: 300TE, 4-speed auto, arctic white, cream-beige MBtex.
201.028: 190E 2.3 Sportline, 5-speed manual, arctic white, blue leather.
201.028: 190E 2.3, 4-speed auto, blue-black, grey MBtex.
201.034: 190E 2.3-16, 5-speed manual, blue-black, black leather.