I had noticed brake fluid loss (warning light and topped off twice), but haven’t seen any drips, and the clutch pedal is occasionally sticking half way back on the return, requiring me to pull it back with my toe. I replaced the Clutch Master Cylinder and bled the clutch, but the sticky pedal still occurred. Yesterday, I removed the slave and noticed leaking fluid, so that appears to be the problem. I ordered and installed a new slave cylinder, with the pedal at the floor, using my Motive bleeder, I bled until no more bubbles, tightened the bleeder tip, pulled the pedal up and gave a few pumps. I released pressure on the Motive, but when I went to start the car, the pedal would not go the last inch or so to engage the clutch/starter sensor. When I pushed harder, the pedal went to the floor and I heard a “pop” and fluid leaking at the tranny. I removed the slave and found the guts in pieces. (see below)
I read that not aligning the slave plunger with the clutch fork can cause this catastrophic failure, so today a bought a new slave, installed it as straight into the hole as possible with the hydro line disconnected and the bleeder valve open. I tightened the mounting bolt, re attached the fluid line, and closed the bleeder valve. With the pedal on the floor, I pumped the Motive up to 22 psi, and bled the valve until no more bubbles. I pulled the pedal up and gave it a few pumps.
I removed the Motive, but the pedal WILL NOT extend the last inch to the floor to engage the started sensor. I don’t want to force it and blow the new slave. What am I doing wrong?
Today, I removed the slave and got my cell cam in position to show the mounting hole and clutch lever (fork). (Below) The indentation in the fork ensures the plunger tip really has nowhere to go but into the divot. I tried to insert my finger to see if I could depress the lever, but the contortion required to get my finger in, eliminates any leverage I have to depress the lever. I don't know if a human finger should be able to depress it. Everything appears to be where it should be, I just don't know it the fork is somehow frozen.
1999 Boxster, 5 Speed, 140,000 well enjoyed miles. The part was purchased from Pelican Parts.
Brand: Sachs, 1999 Porsche Boxster Convertible
Part #: 8E0-721-257-M-M38
Clutch slave cylinder mounting hole - top left side of the transaxle, showing the clutch fork.
I added a dab of lube to the fork indent and the plunger tip and reinstalled the slave... again, connected the fluid line and bled successfully with the pedal at the floor. When I lift the pedal and pump a few times, the pedal will not hit the floor, it stops about 1 inch from the firewall. It feels like the fork is not depressing. Since the clutch pedal will not hit the floor, the sensor will not let me start the car. I did start the car when the cylinder was removed and the pedal was on the floor before reinstalling, but that made no difference.
Any suggestions?
Here are a few shots of the carnage from yesterday’s attempt.
