Clutch slave cylinder piston projectile
 

Because the tolerances were so tight, I had to disconnect my clutch slave cylinder from my transmission to bleed it. All was well until my clutch slave cylinder piston turned into a projectile.

How do I get the piston back into the slave? It is very stubborn and doesnt want to go back in. I am not fighting any hydraulic pressure in this process.

Do I have to put it in a vice and force the piston back in? I want to avoid damaging the rubber boot obviously.

Thanks,
Brian

82' 300TD Wagon w/ Getrag 5 speed

you should
 

be able to use your fingers to push in the rubber skirt a little at a time around the outside edges.

tom w

Yeah, thats what I thought too...

The piston must be stuck on the inside edge of the sleave, or it isnt pointed straight. When I try to work it back into the cylinder, it feels like there is a mechanical hang up, not hydraulic.

Its hard to tell exactly whats going on with the boot in the way. Again, I dont want to screw up that boot seal.

Any ideas?

Brian

If I remember correctly there is a machined grouve in the end of the cyl. The piston is installed then a c/clip is installed in it to stop the piston from falling out. The boot just keeps the dust out and the rod,and from falling onto the floor when uninstalled. I think your piston may have been jammed into the c/clip when bleeding and possibly damaged.

you may
 

just have dirt in the end of the cylinder. you could try taking some emery cloth or wet dry sandpaper and clean the end of the cylinder til the puck slides in easily. use light oil as lube and wetness. clean and oil light ly before assembly.

tom w

I will use the sandpaper method this morning. Hopefully the piston isnt damaged...I guess we'll see.

Thanks,
Brian

if you have raised
 

small burs they too can be sanded off if they arent too big.

tom w

Problem solved
 

I had to remove a clip that had spokes on the outside. Then, the boot came right off along with a substantial amount of black crud from inside the slave.

The piston was fairly scored, and I used light sandpaper and brake fluid to gently polish out the pits. I also did this for the bore. I threw it back together, and now have better clutch response without leaks.

Thanks for all of your advice.
Brian

82' 300TD Wagon w/5 speed

cool
 

good work.

tom w