Well, I can finally tick off another issue off the list. I thought I raised this issue in a separate thread. Anyhow, dug up this old thread to post a resolution. To recap, my better half mentioned the clutch pedal was staying down and needed lifting back up with your foot back in Aug 2012. It was an issue which only occurred when she drove the car so a prioritised it appropriately. Well over the last few months it started to occur when I drove the spider. Can't have that, so it's priority status was raised.
Anyhow, looked for the obvious fluid leakage at the master and slave cylinders, none found and reservoir was at level. Clutch was recently replaced so the slave cylinder was doing its duty, even after manipulating the pedal back up in the car gear selection was fine. So I used my divine logic in diagnosing that the fluid pressure was flowing past the seals in the master cylinder, hence leaving the pedal whiskey limp on the floor. So I ordered a brake master cylinder seal kit off eBay and tackled the overhaul. From the workshop manuals and guides on the web, all indicated access from beneath the car. Having removed various components from beneath and above in the past, I felt it would be much easier to tackle the master cylinder from above. I was right, much easier.
It required removal of the air intake, throttle body, intake runners and the cover over the throttle and bonnet cable levers on the firewall. Even with my massive arms I was able to reach the various bolts along the way. The hardest part was configuring myself into a pretzel to remove the 2 bolts securing the master cylinder in the footwell. Make sure you place some rags to catch any fluid that may escape the cylinder and save your carpet. Also, to catch the damn bolts, the one and only open area near the steering joint is an abyss and sure enough my bolts found there way down behind the carpet.
Anyhow, clutch master out and yes the seals were knackered and only just big enough for the bore of the cylinder. So, opened up my seal kit and the rubbers were all different??? Did my best guess at which ones to use and sure enough it didn't work. After some head and arse scratching I check the seal kit packaging to verify it was for my model Alfa. Yes it was, I read it out aloud to my father I law "brake master cylinder" seal kit - WHAT! He says. OMG I bought the wrong kit.
Damn, late Saturday afternoon, the spider was in the pits again until I could source the right item. Arrrggghh!
Anyhow, a clutch master seal kit seemed non existent on the web so a new cylinder was the next option. Dads neighbour works at a dealership and came back with a trade price of $450. Naff off, not when I could source it for $100 delivered from the UK, but I needed the Alfa on the road and couldn't wait a week for it. The ring around slowly brought its price down until I found it a more respectable price from Domenic at Italian motor spares in Victoria. Highly recommend them, there customer service is second to none. Anyhow, part arrived the next day and I was back one the road in less than two hours. No more whiskey limp clutch pedal.
Sorry for the essay, but I just had to share my homer moment with this fix. I wouldn't call this fix easy, maybe 3 out of 5 spanners. Best tackled from above. At worst you may have to lift the car to reach the intake bolts with long extensions on your socket wrench. Much easier than removing exhaust and half shaft, let alone trying to do hose clamps etc from underneath.
