Replacing the clutch master cylinder on a VAZ 2106

The value of the clutch on the VAZ 2106 is difficult to overestimate. It is the most important system in a car. And if it fails, the car will not go anywhere. The reason is simple: the driver simply will not be able to turn on the desired speed without damaging the gearbox. The clutch on the entire VAZ "classic" is made according to the same scheme. And the key link in this scheme is the clutch master cylinder. It is he who most often fails. Fortunately, the driver can fix this problem on their own. Let's try to figure out how to do it.

What is the clutch master cylinder for?

The only task of the master cylinder in the "six" clutch is to sharply increase the pressure of the brake fluid in the hydraulic clutch actuator. High pressure fluid is supplied to a hose connected to an additional clutch cylinder.

The main clutch cylinders of the "sixes" are made in an oblong cast housing

This device, in turn, allows you to disconnect the chassis of the car from the engine. After this operation, the driver can easily turn on the desired speed and drive on.

How does the master cylinder "six"

The principle of operation is as follows:

1. The driver, pressing the clutch pedal, creates a mechanical force.
2. It is transmitted through a special rod to the master cylinder.
3. The rod pushes the piston mounted in the cylinder.
4. As a result, the cylinder starts to work like a medical syringe and pushes the liquid out through a special hole with a hose. Since the compression ratio of this fluid tends to zero, it quickly reaches the working cylinder through the hose and fills it. Since the driver keeps the clutch pedal depressed to the floor all this time, the total pressure in the system continues to increase.
5. Trying to find a way out, the liquid that has entered the working cylinder presses on the piston of this device.
6. The piston has a small rod. It slides out and engages with a special fork. And she, in turn, engages with the release bearing.
7. After the fork presses on the bearing and causes it to shift, the discs in the clutch drum are separated, and the engine is completely disconnected from the chassis.
8. After disengagement, the driver can freely select the required speed without fear of breaking the gearbox.
9. After engaging the desired speed, the driver releases the pedal, after which the reverse sequence starts.
10. The stem under the pedal is released. The master cylinder piston is connected to the return spring. And under its influence, it returns to its original position, dragging a rod with it, which presses on the pedal and raises it.
11. The working cylinder also has a return spring, which also puts the piston in place. As a result, the total fluid pressure in the hydraulic clutch drops and remains low until the driver needs to change gear again.

The master cylinder is the main element of the hydraulic clutch

Cylinder location

The clutch master cylinder on the "six" is located in the engine compartment of the car. It is attached to the rear wall of this compartment, being slightly above the level of the driver's legs. You can get to this device without any problems, since nothing blocks access to it.

The clutch master cylinder on the "six" is mounted on the wall of the engine compartment

All that needs to be done to remove this device is to open the hood of the car and take a socket wrench with the longest possible handle.

About the choice of clutch master cylinders

If the owner of the "six" started having problems with the clutch and decided to purchase a new cylinder, then the question will inevitably arise before him: which cylinder is better to take? The answer is simple: the clutch master cylinder on the entire VAZ "classic" from VAZ 2101 to VAZ 2107 has practically not changed. Therefore, on the "six" you can easily put a cylinder from the "penny", from the "seven" or from the "four".

Drivers consider it the best option to install standard VAZ cylinders on the "six"

The cylinders presented for sale are also universal, they fit the entire model range of classic VAZ cars. As a rule, motorists try to install original VAZ cylinders. The problem is that the VAZ "classic" has long been discontinued. And parts for it every year becomes less. This rule also applies to clutch cylinders. As a result, car owners are forced to use products from other manufacturers. Here they are:

• FENOX. This is the most popular manufacturer of spare parts for the VAZ "classics" after VAZ. FENOX cylinders can be found in almost every major parts store across the country. These cylinders are reliable and are in constant high demand, despite the somewhat inflated price. If a driver can purchase a standard VAZ cylinder for 450 rubles, then a FENOX cylinder can cost 550 rubles and more;
  

  FENOX clutch cylinders are the second most popular after VAZ
• Pilenga. Cylinders from this manufacturer are found on store shelves much less frequently than FENOX products. But with due diligence, it is still possible to find such a cylinder. The price of Pilenga cylinders starts from 500 rubles.
  

  Finding Pilenga cylinders for sale today is not so easy

And these are all the major manufacturers of cylinders to the "classics" today. Of course, there are plenty of other, lesser-known brands on the aftermarket today. However, contacting them is strongly discouraged. Especially if their cylinders are half the price of the above. There is a very high probability of buying a fake, which will last a very short time. In general, clutch cylinders for the "classics" are often faked. Moreover, in some cases, fakes are performed so skillfully that only a specialist can distinguish them from the original. And for an ordinary motorist, the only quality criterion is the price. It should be understood: good things have always been expensive. And clutch cylinders are no exception to this rule.

As for the installation of cylinders from other cars on the VAZ 2106, such experiments are almost never practiced by motorists. The reason is obvious: the clutch cylinder from another car is designed for a different hydraulic system. Such a cylinder differs both in size and in technical characteristics, the most important of which is the ability to create pressure. The level of pressure created by the "non-native" clutch cylinder may be either too low, or vice versa, too high. Neither in the first nor in the second case does this bode well for the hydraulics of the "six". Thus, the installation of "non-native" cylinders on the VAZ 2106 is an extremely rare phenomenon. And this is done only when it is completely impossible to get a normal VAZ cylinder.

How to remove the clutch master cylinder

The "six" clutch cylinder is a device that lends itself well to repair. In most cases, you can do without its complete replacement. But in order to repair the cylinder, it must first be removed. For this we need the following things:

• set of spanner keys;
• set of socket heads;
• flat screwdriver;
• pliers.

Sequence of operations

Before removing the clutch cylinder, free up space for work. The expansion tank, located above the cylinder, makes it a little difficult to work, so it's best to remove it. It is held on a special belt, which is removed manually. The tank is gently pushed aside.

1. Now the cork is unscrewed on the tank. And the brake fluid inside is drained into an empty container (the most convenient way to do this is with a conventional medical syringe).
   

   It is better to drain the liquid from the expansion tank of the "six" with a syringe
2. The master cylinder has a tube through which fluid flows into the slave cylinder. It is attached to the cylinder body with a fitting. This fitting must be unscrewed with an open-end wrench.
   

   You can unscrew the fitting on the tube with an ordinary open-end wrench
3. Next to the above fitting on the master cylinder body there is a second fitting with a tube connected to the expansion tank. This hose is held in place with a clamp. The clamp is loosened with a screwdriver, the hose is removed from the fitting. It should be remembered: there is brake fluid in the hose, so you need to remove it very quickly, and after removing the hose, you should immediately place it in some container so that the liquid from it does not flood everything under the cylinder.
   

   Remove the expansion tank hose from the cylinder very quickly
4. The cylinder itself is attached to the wall of the engine compartment using two studs with nuts. These nuts are unscrewed with a 13 socket wrench, and the wrench collar should be as long as possible.
   

   To unscrew the fixing nuts of the cylinder, you will need a very long wrench
5. After unscrewing the nuts, the cylinder is pulled off the mounting studs and removed. The device is installed in the reverse order.
   

   After unscrewing the nuts, the cylinder is carefully removed from the studs.

Video: change the clutch cylinder on the "classic"

REPLACEMENT OF THE MAIN CLUTCH CYLINDER VAZ 2101-2107

Complete disassembly of the cylinder

To disassemble the master cylinder, you will need all of the above tools. In addition, a metalwork vise and rags will be needed.

1. The cylinder removed from the machine is carefully cleaned with a rag to remove dirt and brake fluid residues. After that, it is clamped in a vise so that the plug with the nut remains outside. This plug is unscrewed with a 24-mm open-end wrench. Sometimes the cork sits in the nest so tightly that it is not possible to move it with a key. In this case, it makes sense to put a piece of pipe on the key and use it as an additional lever.
   

   Sometimes it takes a lot of force to loosen the cylinder cap.
2. After unscrewing the plug, the cylinder is removed from the vise. On the reverse side of the cylinder there is a protective rubber cap. It is pryed off with a thin screwdriver and removed.
   

   To remove the cylinder cap, it is better to use a thin awl
3. Under the cap there is a retaining ring. It is compressed with pliers and removed.
   

   Pliers are required to remove the retaining ring from the cylinder
4. Now the piston in the cylinder is completely free. It can simply be pushed out with a screwdriver by inserting it from the side of the protective cap.
5. It remains to remove the fitting mounted in the cylinder body. This fitting is held in place by a lock washer. It should be hooked with an awl and pulled out of the nest. After that, the fitting is removed.
   

   There are not too many parts in the “six” master cylinder
6. After replacing the damaged parts, the cylinder is reassembled.

Cuff replacement

As mentioned above, the clutch cylinder is rarely replaced entirely. Much more often, the car owner disassembles it and repairs it. About 80% of cylinder failures are due to a violation of its tightness. The cylinder begins to leak due to wear of the sealing cuffs. So the repair of this device in the vast majority of cases comes down to replacing the seals, which are sold in the form of repair kits in almost all parts stores. The standard VAZ clutch repair kit includes three o-rings and one rubber cap. Such a kit costs about 300 rubles.

Sequencing

All we need to replace the cuffs is a thin screwdriver or an awl.

1. The piston removed from the cylinder is thoroughly wiped with a rag, then washed with brake fluid.
2. The old cuffs on the piston are pry off with an awl or a screwdriver and removed.
   

   It is convenient to remove the cuffs from the master cylinder piston by prying them with a screwdriver
3. In their place, new seals from the kit are manually put on. When putting the cuffs on the piston, it is necessary to ensure that they fit into their grooves evenly, without distortions. If the cuff is still slightly warped during installation, it can be carefully corrected with a screwdriver. If this is not done, the tightness of the cylinder will again be violated and all efforts will go down the drain.

About the choice of brake fluid

When starting to replace the cylinder, it should be remembered: any manipulations with this device are accompanied by leakage of brake fluid. And these leaks will then have to be replenished. Therefore, the question arises: what kind of fluid can be poured into the hydraulic drive of the “six” clutch? It is recommended to fill in liquid class DOT3 or DOT4. The best option both in terms of price and quality will be the domestic liquid ROSA-DOT4.

Most drivers pour DOT4 class fluid into their "sixes"

Filling the liquid is extremely simple: the plug of the expansion tank is unscrewed, and the liquid is poured up to the upper horizontal mark on the tank. In addition, many motorists recommend slightly loosening the fitting on the clutch slave cylinder before filling the fluid. This is done in case a small amount of air has entered the system. When filling in a new portion of the liquid, this air will come out of the system, after which the fitting can be tightened again.

Clutch bleeding procedure

After replacing or repairing both the main and working cylinders, the driver will have to pump the clutch hydraulics, as air enters the hydraulics of the machine. This cannot be avoided. Therefore, you will have to call a partner for help and start pumping.

Sequence of work

For pumping, you will need the following things: an old plastic bottle, a piece of hose about 40 cm long, a ring wrench for 12.

1. The car is installed on the pit and securely fixed. The fitting of the clutch slave cylinder is clearly visible from the inspection hole. A piece of rubber hose is put on this fitting so that the union nut remains outside. The other end of the hose is placed in a plastic bottle.
   

   The other end of the hose is placed in a plastic bottle
2. Now the union nut is loosened a couple of turns. After that, the partner sitting in the cab squeezes the clutch five times. Pressing the fifth time, he continues to keep the pedal depressed.
3. At this time, brake fluid with an abundance of bubbles will flow from the hose into the bottle. As soon as it stops flowing out, you should ask your partner to squeeze the pedal five more times, and then hold it again. This must be done until the liquid coming from the hose stops bubbling. If this was achieved, the pumping is considered completed.
4. Now the hose is removed from the fitting, the fitting itself is tightened, and a new portion of brake fluid is added to the reservoir.

So, the master cylinder is the most important element in the VAZ 2106 clutch system. But its replacement does not require special knowledge and skills, so even a novice driver can handle this task. To successfully replace the cylinder, you just need to show a little patience and follow the above recommendations exactly.