Hi guys,

We just performed a clutch/pressure plate/bearing overhaul (amongst other things) -- I noticed that the clutch slave cylinder extends further in its 'default' setting ( read: clutch not pressed) than it did before the clutch job. When I press the clutch, the piston comes out so far that the rubber gaiter/protection is extended to its maximum. This worries me a bit, as I cannot seem to think of a reason why this would be (except for different release bearing height or something).

Can any of you guys help me out here? Is this normal and if not, what could be the cause?

Thanks a lot!

 

BTW: I replaced the regular 850 clutch with a 850R clutch kit (pressure plate & clutch disc). Maybe that makes a difference?

 

A thicker clutch disc (like a new one) will cause the "fingers" on the pressure plate to contract closer to the flywheel and consequently the release bearing is closer to the flywheel. When the clutch disc wears the slave piston will change to where you used to see it.

 

Thanks for responding! This was exactly my thinking, but thus far I mainly got responses from people saying it is a bit more extended than it should be. Therefore, I made a video displaying how far the piston extends from the slave cylinder:
Is this acceptable? I have no idea how far the piston can extend before popping out...

 

I believe there were 2 or 3 different lengths for that pin. I had a problem with this and the piston came out a couple times before I made a longer pin. If that piston comes out, it sticks first (mine did). You'll be stuck. But if you can dislodge it, then you'll have engagement all the the time, and you'll have an adventure getting it home.

So I advise cheating here. Get a little longer bolt in there.

 

Could this be the source of an issue I am having currently? It looks like someone put a new slave cylinder on this car at some point and I think it’s causing the slave to not disengage the clutch. I cannot put the car in gear when the engine is on.
This is my thinking.

 

Well, with a hydraulic clutch your first assumption is you have a fluid problem. That's the usual. Could be a leak leading to low fluid, or the slave or master went bad. If the cylinder comes so far out of the cylinder that all the fluid exits that way, then you get into geometry like we are talking about here.

 

My thinking was the pushrod pin, you said there were multiple lengths? I installed a new master cylinder and hydraulic line but not the slave as it appears to be in good condition, I’ll probably end up replacing it regardless if the problem persists.
I haven’t tested the new setup yet but I can only imagine the problem will persist, I can feel it in my gut.
Where did you find the pin came in different lengths?

 

consequently the release bearing is closer to the flywheel. When the clutch disc wears the slave piston will change to where you used to see it.