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Re: Converting to manual trans with hydro clutch
jcd74 #799279 December 04th 2022 1:59 pm
Joined: Mar 2011
Posts: 460
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jcd74 Offline OP
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So the computer died and I am once again searching for pics.

[Linked Image from live.staticflickr.com]

I drilled new holes in the crossmember for the tranny mount

[Linked Image from live.staticflickr.com]

I had the driveshaft cut.

[Linked Image from live.staticflickr.com]

Located the spot for the shifter. it was 16" from the mating surface of block and bellhousing.

[Linked Image from live.staticflickr.com]

I jacked it up where I believed it needed to be. I used 2 thoughts here, 1 driveshaft angle. I have the 2 piece shaft so the back half angle is the most important. I did not alter the length of the back, the support bearing and back shaft went back where I found it. The 2nd is the difference in space between the mount and the center of the output shaft. I found it to be 3 7/8". I went with 4" in theory to take a little angle out of the driveshaft. If both thoughts where in agreement I moved forward.

[Linked Image from live.staticflickr.com]

I made some spacers to drop the crossmember down. I used 4x4 1/4 thick steel post from the steel yard. It's overkill but it's all I could find. I capped both ends in 1/4 plate and added more 1/4 plate to the sides for mounting. Feel free to make fun of the welding, I do.

[Linked Image from live.staticflickr.com]

I located the holes and had at it. This is the result.

[Linked Image from live.staticflickr.com]

Dragged it home and did a "on the try", measured the angle and was happy with the result. Transmission installed, time to move onto the hydro clutch.

1 member likes this: frscke1
Re: Converting to manual trans with hydro clutch
jcd74 #799288 December 04th 2022 7:44 pm
Joined: Sep 2005
Posts: 9,683
Likes: 145
carpal tunnel
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carpal tunnel
Joined: Sep 2005
Posts: 9,683
Likes: 145
Your welding is much better than mine.....
Looks good.

Love the sofa too. Just can't have a proper garage without an old sofa.... cool

Re: Converting to manual trans with hydro clutch
jcd74 #799301 December 05th 2022 7:44 am
Joined: May 2018
Posts: 2,397
Likes: 61
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or a proper front porch CatFish.


When in doubt..get the sawzall out..
Re: Converting to manual trans with hydro clutch
jcd74 #799531 December 11th 2022 5:52 pm
Joined: Mar 2011
Posts: 460
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J
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Posts: 460
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That's the uncle's old shop. That side is the owners storage dept and hide from the wife and kids.

Re: Converting to manual trans with hydro clutch
jcd74 #799537 December 11th 2022 7:23 pm
Joined: Mar 2011
Posts: 460
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jcd74 Offline OP
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So hydro clutch. I can find no example of it being installed in any 73-95 Chevy van from the factory. Everyone that ever posted a pic thank you for the help. With all the searching I did there are two things that convinced me of this, one was I saw they offered a cable around 90 up and the second was a guy in England on fake book that said his van used the cable. At that point I gave up looking for it. The parts sites will show you a master cylinder and the repair manuals will give an example how to bleed it.

[Linked Image from live.staticflickr.com]

I started with this, the lower is said to be from 78 and the upper is from my van.

[Linked Image from live.staticflickr.com]

I took it apart and slapped the clutch pedal on for some measuring.

[Linked Image from live.staticflickr.com]

I went to the store bought a cheap plastic miter box, plastic sheet and some grease pencils.

[Linked Image from live.staticflickr.com]

If you look up ticking stick, joggle stick, it is a old method of measuring and copying shapes. This can be useful for interior work where you want to find the shape-curves on the wall of your van.

[Linked Image from live.staticflickr.com]

You trace around the stick and get your points of interest.

[Linked Image from live.staticflickr.com]

Lay the pattern and stick down, line the stick to your marks and connect the dots.

[Linked Image from live.staticflickr.com]

I now have a drawing and start filling in the blanks. It only gives you a 2 dimensional point of view but it helps. I wanted the clutch rod to be straight with the cylinder at the end of travel for no side wear of the piston. I could find the length of the clutch rod and so forth.

[Linked Image from live.staticflickr.com]

Slightly better pic.

[Linked Image from live.staticflickr.com]

Slapped this together.

[Linked Image from live.staticflickr.com]

I ordered some 3x3 aluminum block and made a wedge to line up the master with the rod.

[Linked Image from live.staticflickr.com]

Seems good?

[Linked Image from live.staticflickr.com]

[Linked Image from live.staticflickr.com]

Drilled some holes.

[Linked Image from live.staticflickr.com]

Made it up to here so I could go outside and eyeball things.

1 member likes this: frscke1
Re: Converting to manual trans with hydro clutch
jcd74 #799538 December 11th 2022 7:52 pm
Joined: Jun 2010
Posts: 17,211
Likes: 212
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Posts: 17,211
Likes: 212
WOW nice ....


SUNSHINE VANS-VAN DIEGO
ADRENALIN BY THE GALLON & CHASIN RACIN
ONE FOR THE DIRT & ONE FOR THE STREETS
'93 CHEVY G30 454 4X4 SPORTVAN EXT 146" WB
'92 CHEVY G30 454 BEAUVILLE EXT 146" WB
Re: Converting to manual trans with hydro clutch
jcd74 #799567 December 12th 2022 7:47 am
Joined: May 2018
Posts: 2,397
Likes: 61
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That is a ton of work, nice job.


When in doubt..get the sawzall out..
Re: Converting to manual trans with hydro clutch
jcd74 #800887 January 23rd 2023 6:51 pm
Joined: Mar 2011
Posts: 460
Likes: 27
J
jcd74 Offline OP
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I have given up trying to get the other pics out of the broken phone, the ones I have will have to do. Now a couple things on theory. You need to define pedal ratio, it is the ratio of the pedal arm and the upper clutch rod lever. Measure the distance from the pivot to the center of the pedal pad. I got a whopping 14 and 1/4 inches. Online they state a pedal ratio between 5 and 7 to 1 is ideal. I picked 6 to 1, so we divide 14.250" by 6 and we get 2.375 or 2 and 3/8. I need to make the upper clutch lever 2 and 3/8, pivot point to clutch rod pivot point. If you look in the photo you will see a circle marked out at 2 3/8. [Linked Image from live.staticflickr.com]

Sorry I picked the big one hope you can see. Now the thing with gm and I don't know if this applies to all vans but the upper clutch rod faces forward and pulls, I need it to push. Most of the master cylinders work in push. You can try to find a pull cylinder but it was not for me. I am using the same slave cylinder that came with the tranny, a quick look up of the donor truck showed it is a .71" cylinder. So .71 is my starting point. Keep it simple. I hate to admit but I have about 600 in master cylinders!

Re: Converting to manual trans with hydro clutch
jcd74 #800888 January 23rd 2023 7:27 pm
Joined: Mar 2011
Posts: 460
Likes: 27
J
jcd74 Offline OP
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If you look to the left of the gas pedal you can see the four dimples, this would be the stock clutch rod location. I drilled a 2" hole in the center dimple and tried the master and wedge block I made.

[Linked Image from live.staticflickr.com]

[Linked Image from live.staticflickr.com]

I made a plate to help stiffen the floor area and used a 2'" drum sander to open up the hole.

[Linked Image from https]

I got some steel bushings and ground them on an angle so the bolt heads sit flat on the equipment. just a couple tacks welds to hold them on to the plate. The wedge needed some clearancing.

[Linked Image from live.staticflickr.com]

[Linked Image from live.staticflickr.com]

Onto another try, it fits.

[Linked Image from live.staticflickr.com]

[Linked Image from live.staticflickr.com]

Trying the clutch rod to eyeball again.

[Linked Image from live.staticflickr.com]

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