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  #1  
Old 02-05-2009, 02:15 AM
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Manual Tranny - Won't go into any gear when cold

On several occasions lately, after starting the car and putting my foot on the clutch, I find that it refuses to go into gear (any gear). I then let my foot off the clutch, and depress it a second time, and it goes right in and operates just fine. Other than that, I'm not having any other problems. The tranny fluid is full and fresh, the brake fluid reservoir is full, and the clutch appears to be disengaging fully. This just started in the last week or so, and only happens when the car is cold (mid to low 30s outside). I really don't know why this would suddenly become a problem, since it's been this cold in the mornings for several weeks. Any ideas?

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  #2  
Old 02-05-2009, 03:03 AM
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Iam thinking if this just started, and you have full and fresh fluid, then either the Master cylinder or the Slave cylinder may be leaking off some.
Or fluid is by-passing internally when it sits for a while.

Pushing the peddle a couple times pumps it up.

Iam 3 hrs from you,by santa Cruz. we haven`t been all that cold compared to back east. So I don`t think that is an issue.

Charlie
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there were three HP ratings on the OM616...

1) Not much power
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Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

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  #3  
Old 02-05-2009, 06:06 AM
t walgamuth's Avatar
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Yes, thats an indication of a worn clutch master or air in its lines.
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..I also have a 427 Cobra replica with an aluminum chassis.
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  #4  
Old 02-05-2009, 10:08 AM
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Pull the carpet down between the pedals and check for brake fluid on the hard line to the master cylinder. It does sound like either master or slave has gone south.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
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1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

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  #5  
Old 02-05-2009, 04:17 PM
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Thats more or less what I was thinking. I don't know how old the fluid is in the system. It could be ancient for all I know.

A few questions:

- Would old fluid potentially cause this type of symptom?
- I know that the brake and the clutch systems share the same fluid, but do they also share the same master cylinder?
- Is there a way to determine whether the problem is with the master cylinder or the slave cylinder?

I will check for leaks when I get home.

Thanks.
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1982 240D - 292,000 miles and counting
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Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks
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  #6  
Old 02-05-2009, 05:46 PM
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Quote:
Originally Posted by mjquillici View Post
Thats more or less what I was thinking. I don't know how old the fluid is in the system. It could be ancient for all I know.

A few questions:

- Would old fluid potentially cause this type of symptom?
- I know that the brake and the clutch systems share the same fluid, but do they also share the same master cylinder?
- Is there a way to determine whether the problem is with the master cylinder or the slave cylinder?

I will check for leaks when I get home.

Thanks.
The reservoir above the master cylinder has two chambers. The back one with the hose coming out supplies the clutch master. Its hard to see the level, shake the reservoir a little. Its a common mistake to neglect it since its so hard to see, once you have too bleed the clutch your usually more attentive
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #7  
Old 02-05-2009, 06:05 PM
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Cool. I will check it out. Is it completely isolated from the brake reservoir?
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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks
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  #8  
Old 02-05-2009, 09:17 PM
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[QUOTE=mjquillici;2101367 Is it completely isolated from the brake reservoir?[/QUOTE]

No, The reservoir is actually split into two chambers.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #9  
Old 02-05-2009, 09:28 PM
t walgamuth's Avatar
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A bad clutch master can make this symptom and have no external leaks. IMHO its unlikely that old fluid would make this symptom....impossible, I believe, actually.
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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.
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  #10  
Old 02-05-2009, 09:38 PM
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Got it. So, if the fluid level is at the max fill line on the front part of the reservoir (farthest from firewall), I should have plenty of fluid for both brake and clutch? In other words, can it appear full, but really not be?

Also, how would one go about diagnosing a bad master cylinder from a bad slave cylinder?
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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks
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  #11  
Old 02-05-2009, 10:31 PM
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Quote:
Originally Posted by mjquillici View Post
Got it. So, if the fluid level is at the max fill line on the front part of the reservoir (farthest from firewall), I should have plenty of fluid for both brake and clutch? In other words, can it appear full, but really not be?

Also, how would one go about diagnosing a bad master cylinder from a bad slave cylinder?
There are TWO chambers, in the reservoir both should be full. Look very carefully and make sure the aft chamber has brake fluid in it.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #12  
Old 02-06-2009, 06:33 AM
Admiral-Third World Fleet
 
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Quote:
Also, how would one go about diagnosing a bad master cylinder from a bad slave cylinder?
It is pretty hard to be sure which one is bad, unless one or the other is leaking very badly. And even then, you are probably better off to replace them together.

I have been fighting clutch hydraulics issues since summer. I rebuilt the master cylinder (twice) then replaced it when I figured the kits I had weren't probably the right ones. Then the new M/C worked for 2 weeks (but felt a little softer than the old lashup when it was working properly). Now the pedal is really low so I'm going in there this weekend and replace the slave with a new one. Can you imagine how much time and brake fluid I have wasted in all this?

Rick
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  #13  
Old 02-06-2009, 09:51 AM
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I, also, dont know how you could tell which is at fault, master or slave. The slave is allot easier and cheaper so I would start there. Unless your down to your last dime buy new ones.

But first make sure you didn't just run out of fluid.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Last edited by Stevo; 02-06-2009 at 09:59 AM.
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