Update. Bit of a long read, but it's pretty much everything about the struggle to sort the heavy clutch pedal from day one. Those who already know the story can skip to just under the first pick.
Some of you will know that ever since I got the car I've had big problems with the super heavy clutch pedal. I talking knee hurting heavy here. My knee started with some aching not long after I got the car and started hurting a few weeks ago because of clutch.
Shortly after I got the car I took it to a guy here in Somerset West and he said that it could only be the clutch it self, or the splines to be more specific. BMW wanted about R9k for a clutch kit. Yea right...
Then the slave cylinder failed and I had the same mechie replace it and it made no change to the heavy pedal. Time goes on and then one day there's a bang and the pedal drops to the floor while I'm in traffic. The clutch fluid line exploded. So I took the plunge and ordered a clutch kit from the USA (about R5200 + shipping and customs and it's exactly the same as what you get from the stealers) and have the same mechie fit a new line and the clutch kit. 3 weeks later I can drive the car again and wouldn't you know it... the pedal is still just as heavy.
Then Rick540 said that the car might have the wrong slave cylinder and that it was probably replaced with the wrong one by one of the previous owners. Now here's where things get a little interesting...
RealOEM does not list our E34 540i 6 speeds with a manual box... there's only a auto to choose from even if you put the vin in. Not even Rick540 could find the correct info. So... I looked at the Europe 6 speed and there they list that the slave should be 26mm. The one on my car was 20mm. I know this because the company the mechie got the slave from only lists the one slave for all E34's. So it's kinda not his fault for fitting the wrong slave, but at the same time I feel he should have made sure with a car this rare.
I searched high and low and for quite some time, but couldn't get the correct size slave anywhere but the agents. Eventually I got the correct slave cylinder from BMW... only R2150 :mmm:
Once I opened the box I couldn't help but think that it's pretty huge. Here's a pick of the cylinder next to a CD cover:
So this past weekend I was on a mission to swap out the old cylinder with the new one. Did all sorts of research and PM'd Rick540 to make sure I've got everything covered for a nice smooth swap. So I get the car in the air, put down some news paper and a towel to lie down on and crawl under the car. Take my torch to have a good look and I see the nut is slightly damaged. At this point I pretty much knew I wasn't getting it off, but I tried anyway. So I take the 11mm spanner and carefully have a go. It's WAY to tight and I can't use the ring side of the spanner as there's a pipe going right through the middle of the nut I need to loosen. Man, was I pissed.
So I took the car to the same mechie mentioned above and who worked on it last. Told him that I've spend close to R10k with parts and labour on what he said and that I would like him to swap out the cylinders.
So this morning he does so:
Now it might just be that I'm not used to it, but I think it might almost be easier than my 318's pedal.
I do think that it needs a more proper bleed as there is some play on the pedal. For about 2cm it's just loose and rests on the pressure (not sure if this makes sens). I also think it's a little spongy at the top, but I may just need to get used to it. Will see.
Right now I'm just ssssoooo relieved that I've finally got it sorted and hopefully my knee will ache less now. Trust me... think of a heavy clutch you might have came across in your time... mine was heavier. Some the guys here can back me on this.
