Master cylinder failing is quite rare, its usually the slave cylinder that always gives up
“The Blue Elephant” My Safari 4x4 Review & Mods
- Thread Starter bhvm
- Start date
Sorry, my bad. How could I forget. ![[embarass]](https://www.theautomotiveindia.com/forums/images/smilies/Embarass.gif "Embarass [embarass]")
Despite of :
XUV =hydraulic clutch with concentric slave cylinder.
Nexon =hydraulic clutch with concentric slave cylinder.
Despite of :XUV =hydraulic clutch with concentric slave cylinder.
Nexon =hydraulic clutch with concentric slave cylinder.
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Thread Starter
#378
Agreed. Its weird. and the way it failed is also weird.
Thankfully Safari uses a oldschool truck type (non concentric) slave where the slave sits outside the gearbox, and connects vie a shaft to move the clutch. No teardowns necessary for replacement!
Thankfully Safari uses a oldschool truck type (non concentric) slave where the slave sits outside the gearbox, and connects vie a shaft to move the clutch. No teardowns necessary for replacement!
Thread Starter
#379
Update on clutch issue.
Yesterday I received the parts from boodmo and went running to ASC for getting my beast back on track. With hopes that I might have a "gift" for Christmas. And atleast have a drive or two.
Removing the Master & Slave cylinder took some time as they are located awkwardly and its hard to get wrenches in.
Upon removal, We found the cylinders to be actually good. Which is super strange. The pistons were working.
On closer inspection and to my Horror, We found out that the slave cylinder (which sits on a clutch fork and actuates the fork to release the clutch) has ended up damaging the clutch fork itself!.
Initial diagnosis looks puzzling & Grim.
![Clutch fork VID-20221224-WA0003.mp4_snapshot_00.04_[2022.12.25_16.59.05].jpg](https://www.theautomotiveindia.com/forums/attachments/clutch-fork-vid-20221224-wa0003-mp4_snapshot_00-04_-2022-12-25_16-59-05-jpg.305659/)
![Clutch fork VID-20221224-WA0003.mp4_snapshot_00.14_[2022.12.25_16.59.15].jpg](https://www.theautomotiveindia.com/forums/attachments/clutch-fork-vid-20221224-wa0003-mp4_snapshot_00-14_-2022-12-25_16-59-15-jpg.305660/)
I have never heard of this kind of failure despite using Safaris since 98. Nor has the Mechanic.
The mech suggested that such awkward failure is only possible of something is further damaged in the clutch cover or gearbox and has ended up giving a strong strike to clutch fork, causing it to move out of range and causing a catastrophic failure. I can now imagine (with my Paining head) broken pieces of something, flying in the gearbox bell housing.
Well, if you think thats the end of bad news, Here is more.
Since this repair calls for removal for Gearbox and Gearbox is situated behind the 4x4 assembly, the said assembly will have to removed too.
Removing the 4x4 is a complicated process and costs 6k just for labour.
But wait, it get worse,
Since removing the 4x4 system requires a better equipped & trained workshop, I will have to tow the beast to a larger city and get it done there.
Sigh.
Yesterday I received the parts from boodmo and went running to ASC for getting my beast back on track. With hopes that I might have a "gift" for Christmas. And atleast have a drive or two.
Removing the Master & Slave cylinder took some time as they are located awkwardly and its hard to get wrenches in.
Upon removal, We found the cylinders to be actually good. Which is super strange. The pistons were working.
On closer inspection and to my Horror, We found out that the slave cylinder (which sits on a clutch fork and actuates the fork to release the clutch) has ended up damaging the clutch fork itself!.
Initial diagnosis looks puzzling & Grim.
I have never heard of this kind of failure despite using Safaris since 98. Nor has the Mechanic.
The mech suggested that such awkward failure is only possible of something is further damaged in the clutch cover or gearbox and has ended up giving a strong strike to clutch fork, causing it to move out of range and causing a catastrophic failure. I can now imagine (with my Paining head) broken pieces of something, flying in the gearbox bell housing.
Well, if you think thats the end of bad news, Here is more.
Since this repair calls for removal for Gearbox and Gearbox is situated behind the 4x4 assembly, the said assembly will have to removed too.
Removing the 4x4 is a complicated process and costs 6k just for labour.
But wait, it get worse,
Since removing the 4x4 system requires a better equipped & trained workshop, I will have to tow the beast to a larger city and get it done there.
Sigh.
The pics are not making it clear about what is damaged and how much is damaged. Maybe I don't know exactly what to look for.
Sorry to hear about the problems your beast is facing. And I am worried there may be more problems coming out when everything is dismantled. I pray that it wont be so.
Good thing is that once everything is put back ,your clutch related issues, which have been troubling you for quite some time, might get solved once and for all.
Sorry to hear about the problems your beast is facing. And I am worried there may be more problems coming out when everything is dismantled. I pray that it wont be so.
Good thing is that once everything is put back ,your clutch related issues, which have been troubling you for quite some time, might get solved once and for all.
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Thread Starter
#381
The above image is a clutch fork. The hollow area in the middle houses the drive shaft & clutch bearing.
This fork lifts the clutch when pedal is pressed.
This zoomed in area has a divot where the slave cylinder applies force. As you can see in earlier images, the divot area has been drilled through by the slave cylinder shaft.
This is what a slave cylinder looks like. The protruding shaft presses onto the clutch fork where the divot is.
I did'nt have any clutch issues before this. Just that safari clutches are normally quite stiff. The design is based on TATA 407 truck. Lots of parts were actually interchangeable between Safari 3.0L, Tata mobile 207 and Tata 407.
OK, your master cylinder ordeal confused me. I presumed it was related to clutch. Apparently not.
Thread Starter
#383
This was related to brakes.
Thread Starter
#384
Thanks @bhvm for the video.
I have this product, purchased last year when I found my car seat got coated with mold & fungus and kept one pack in my car. However, by mistake I pulled out both the aluminium foil and the white safety cover. The result was, in a few days it all melt down and become a pasty liquid.
Two packs still left with me and now I am going to keep one in my car (the proper way as you explained in the video). It has been raining here since last few days and little bit mold started to develop.
I have this product, purchased last year when I found my car seat got coated with mold & fungus and kept one pack in my car. However, by mistake I pulled out both the aluminium foil and the white safety cover. The result was, in a few days it all melt down and become a pasty liquid.
Two packs still left with me and now I am going to keep one in my car (the proper way as you explained in the video). It has been raining here since last few days and little bit mold started to develop.
Another old hack is put camphor underneath the floormat, it will absorb any moisture and bad moldy odour.