Charlie,
On my cars there is a bit of tension between the clutch shaft rod and the
slave cylinder piston. I assume this tension is what keeps the piston from
sliding out, as there is no circlip to hold the piston in the cylinder. Seems
like it is a geometry problem and either the rod is too short or the slave
cylinder is mounted improperly. disc you mount the slave cylinder on the REAR of
the bracket?
That's all I can think of now.
Good luck,
Jim Davis
Charles and Linda Duckworth wrote:
> Two weeks ago I completely replaced the clutch system, pilot bushing, throw
> out bearing , pressure plate and release fork and clutch pedal hole. Clutch
> was great but starting 'popping' or dragging coming out of first gear or
> reverse - I later found this to be the pushrod was too tight on the clutch
> shaft and was binding so I pried the two legs apart so it didn't stick or
> rub on the shaft arm Last night after my son's little league practice the
> piston pushed out of the slave cylinder up to the rubber washer - with part
> of the washer sticking out. I managed to get it back in, added some fluid
> and drive home in first gear. btw the pushrod is attached to the middle
> hole in the shaft.
>
> Today after coming home from work I pulled the piston out cleaned it up and
> had my wife help me bleed the system and drove around for 10" and everything
> was again 'right with the world'...shifting like a new car, I stopped,
> reverse, forward several times to make sure it was fine . After 15" in the
> house I decided to run my son up to the store and the slave cylinder
> repeated the same problem as the night before backing out of the garage (vs.
> two miles away. The piston is pushed out of the cylinder about 3/8" and the
> rubber washer is sticking out in one area - allowing the brake fluid to
> stream by.
>
> The pushrod is brand new, the slave cylinder was put in last year but I had
> to tap it with a hammer several times to get the piston to return to the
> back last night and again today. Given the above should merely spend the
> $40 for a new slave cylinder given this one might be bad? or is there
> another reason for the piston coming out the back of the cylinder I should
> look for as well?
>
> Charlie (about ready to drink a 6Pack due to this car)
> 1976 TR-6
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