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Ordered a MC thinking that's what the problem was, but got to spend some time on the car today, and it is the slave. Once I popped the boot off, my precious blue fluid came pouring out! That little boot made a better seal than some gaskets I have used! So, time to order the slave. I guess I have a mc to shelf if it ever decides to bail on me.

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So, I ordered a replacement slave from rock auto. In the mean time, I took mine out to see what was going on. I bought the current slave new back in July. After taking it out, I did confirm what Billy said. There was no circlip holding in the piston. However, if you notice in the photo below, there is a groove under just under the end of the slave that gets covered by the rubber boot. The first bevel of this rubber boot is enough resistance to hold the piston in place during installation. What I did was install a metal tabbed zip-tie to hold this boot onto the slave. If this pops again, I will switch to using a metal pinch clamp (I just didn't have one to use today). Looks like the main thing that keeps the piston from dislodging is the pressure from the bearing fork itself, but the rubber boot must provide some help as well. As Billy also stated, maybe a slightly longer actuator rod would help even with the slave that does not have the circlip. The spring inside the slave will obviously be compressed before the pressure plate receives any pressure.

First pic, slave with no boot. You can see the piston just coming out of the end (my index finger hold it in).

11501537463_58ae85c0e3.jpg

This pic shows the boot installed with the zip-tie adding additional clamping power. Note: The zip tie must be installed after you fit the slave onto the transmission, as it will not fit through the mounting hole.

11501451335_64124bfa47.jpg

if this doesn't hold, I'll report back!

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So, I ordered a replacement slave from rock auto. In the mean time, I took mine out to see what was going on. I bought the current slave new back in July. After taking it out, I did confirm what Billy said. There was no circlip holding in the piston. However, if you notice in the photo below, there is a groove under just under the end of the slave that gets covered by the rubber boot. The first bevel of this rubber boot is enough resistance to hold the piston in place during installation. What I did was install a metal tabbed zip-tie to hold this boot onto the slave. If this pops again, I will switch to using a metal pinch clamp (I just didn't have one to use today). Looks like the main thing that keeps the piston from dislodging is the pressure from the bearing fork itself, but the rubber boot must provide some help as well. As Billy also stated, maybe a slightly longer actuator rod would help even with the slave that does not have the circlip. The spring inside the slave will obviously be compressed before the pressure plate receives any pressure.

First pic, slave with no boot. You can see the piston just coming out of the end (my index finger hold it in).

11501537463_58ae85c0e3.jpg

This pic shows the boot installed with the zip-tie adding additional clamping power. Note: The zip tie must be installed after you fit the slave onto the transmission, as it will not fit through the mounting hole.

11501451335_64124bfa47.jpg

if this doesn't hold, I'll report back!

when i got my manual swap. i install the used part including the slave cylinder. the slave cylinder piston was more than half way out. all i did was push back the piston with the rod and install it. didn't have a problem. i think if you guys are having problem where the piston come out to far and cause it to leak than probably something is not right. once install it don't suppose to travel that far out. maybe you need longer rod. something is not right with the clutch setup. maybe missing the white piece that the shift fork sit on causing it to travel out farther.

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Hope it works for ya! It should, I just got tired of the piston coming out and my slaves had no groove to put a circlip in so I got the one with the clip, I've luckily been problem free so far (knock on wood) and we'll see what happens. A longer rod probably would solve it too. Cheers,

Billy

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