New clutch...slave cylinder keeps bursting
 

I just replaced the clutch in our Boxster, but when I stepped on the clutch pedal the slave cylinder burst. I replaced the slave, bled the system and it did it again.

Anyone ever experience this that knows what the cure is?

Thanks! :cheers:

I hate to say this, but are you sure you reinstalled everything correctly? Only time I've ever encountered this is when the fork could not depress the pressure plate because something was jammed, so the slave blows out from excessive pressures.

Pull the slave and make sure the fork can be moved freely; if does not, time to pull it all apart again........

I had something similar happen when spec sent me the wrong pressure plate

I'm not pushing the clutch pedal very hard so it acts like the slave is missing the release lever.

Can the slave be put back together if this is the case instead of getting a new one? I can do that with the 928 slave cylinder so I'm hoping it's the same with the Boxster slave.

oh, i thought you were blowing the seal. if you just hyperextended the slave pushrod, you can reassemble the cyliner with no issues.

as to the nature of the problem? the simplest possibility is that the pushrod wasn't properly seated in the release lever cup. since this happened twice, though, i'm guessing you may have a different issue.

unfortunately, the rest of the issues require removal of the transmission. it's possible that your throwout bearing has come loose from the release fork.

Thanks. I went ahead and ordered another one and will take everything apart again this weekend. I've never had to check if the release lever would move properly since it's all one pack in the 928. Didn't think about that since the Boxster puts it together when you put the transmission in.

Should I start the engine and let everything engage before I push on the clutch pedal for the first time? I'll check the levers and such, but it's odd to me that the release bearing is not attached to the pressure plate so this setup is unfamiliar.

Thanks for the help!

it's also possible that the lever has somehow slipped off the fulcrum & it's canted over to the side a bit. you should be able to put your finter right into the release fork cup through the slave passage. if it's not right there, you have a problem.