Turbo 616 powered Astro Van build

JB3

Superturbo

1,795

06-06-2013, 12:35 PM #173

(05-31-2013, 11:51 AM)Simpler=Better Can you swap in a larger clutch MC? More volume at the pedal would give you more movement at the slave. I'm sure the astro guys would take your old stock MC

Getting there with the stock master slowly. If I went with another one I might have to weld ears onto it to bolt oddly as its set up on this van, however im doing kind of what you are saying in a different way via altering pushrod length, described below-

small update-

So the first thing I did to try and get the clutch was move the bolt for the master to the pedal into the lower of the two holes on the pedal and get that much further swing. That did nothing, with the engine running I could not get it into gear.

Then looking over the clutch system, I remembered that the push rod for the GM slave is actually a separate piece, a little steel dowel, and why not just put in a longer push rod for the same result?

I pulled out the stock pushrod that came with the slave, which is about 4.5 inches, and have been making progressively longer pushrods by 1/4 inch increments.

4.75 inches got me an ominous click and no gears with the pedal depressed
5.00 inches got rid of the ominous click, but still no gears
5.25 inches got me able to get it into 3rd and 4th if you work at it, and no other gears
5.50 inches got me much easier into 3rd and 4th, and as hard as 5.25 into 1st and 2nd, but no 5th, and no reverse. In those gears clutch engagement seems decent.

Ive been slammed with work, so after that had to quit, but I think 5.75 or even 6 inches will be the golden pushrod length for this clutch. Ill post back when I actually can get it into gear finally and drive around.

Meanwhile, I resolved the massive valve cover leak, and a new massive leak has presented itself from the pressure outlet of the remote oil plate around the threads. That will have to be removed and fixed. Additionally, I have the turbo working now, properly (finally) hooked up the air line from the intake to the ADA, and it spools.

With my sudden work schedule ive been unable to do anything about this van for a week, but i hope to get back to it next week or this weekend and start fixing issues and get it drivable. It now starts like a dream though

1974 240D 617 turbo swap, W201 5-speed, in the works project
1983 240D 616 stock, DD
1989 Chevy Astro, 617 turbo swap, T5 5-speed, 4.56 diff, work van