Hey there, i have a 94 3.0L that’s 4x4 and manual with 140k and I have replaced the clutch, slave cylinder and master cylinder and every time I push down the pedal it explodes some seal. Everytime it runs it dumps brake fluid from the bell housing and this is the second time I’ve replaced the slave cylinder and I don’t want to have to pull the transmission again but knowing I have to I need to find out what’s wrong. Being a new clutch I did use an alignment tool and the flywheel was in great shape and was even torqued to spec, new master cylinder was bench bled properly. same goes with slave cylinder. My guess is I messed but with alignment or missed something. Any ideas?

symptoms: brake fluid from bell housing when running, when connected at first it feels right and then there’s a pop and pedal goes to floor, able to move but barely, starts great, shifts into all gears

 

It might just be bad, the slave cylinder. Could it be backwards?it sounds like you did everything right

 

Could be but 2 in a row seems unlikely

 

Yeah for sure something definitely wrong. I’m sure you’ve checked YouTube for info. The only thing I can think now is maybe there’s something wrong with the clutch plate? I do have an idea maybe I know it’s a lot of work, but if you removed it, you could try it with it not installed and see what happens or if you got a new one you could also try it before you put it in. Do you think that the clutch could be in backwards? The clutch plate?

 

Are you sure you installed the clutch release (aka throwout) bearing onto the slave cylinder? That should keep the seal in the cylinder (so long as it bumps up against the clutch), but without it the seal will just get pumped out. When I bench bled my master cylinder the seal in the slave cylinder was in crooked and fluid would pump past it. I had to use the clutch release bearing to get the seal square with the cylinder.