[Mgs] clutch saga continues

[Paul Hunt]

I don't believe this is possible, without extreme pressure being applied to
the clutch pedal, far more than one would apply to the brakes under emergency
braking.

At one point you said after replacing (I think) the slave cylinder you had
'normal' pedal pressure which I can only take to mean the pedal was also
moving up and down normally.  If this is the case then the TOB cannot be
seized or otherwise jammed, which in any case is nothing to do with the
friction plate being rusted to either the flywheel or cover plate.

With the slave cylinder disconnected from the bell-housing, of even if it is
still attached, normally you should be able to pull the release arm forwards
and so push the slave piston further into its cylinder.  When released the
spring inside the cylinder should push the piston back out again, and so take
up any free play in the release arm, which incidentally can suck air past the
seal into the cylinder which will then need bleeding again.  If you remove the
cylinder from the bell housing you should be able to push the release arm back
and fore freely.  If you can't do this i.e. the release arm is stuck fast then
your problem is indeed inside the bell housing, and so the clutch can't have
been operating 'normally' at any time.

There is another cause of fluid coming out of the slave boot and that is when
the release bearing, arm or clutch are incorrectly installed which allows the
release arm to pivot too far backwards which allows the piston to get pushed
out of the end of the cylinder.  Or possibly the push-rod is incorrect and way
too short, or the slave is the wrong one and positioned too far forwards for
the length of the push-rod, and so on.  That is the only time the seal can get
cocked in the bore.  But again this isn't a stuck release arm, but one which
pivots back and fore much more than it should, along with the TOB.

PaulH.
  ----- Original Message -----
  it looks like the tob is not moving.  the buildup in pressure in the
original
  and new slave cylinder is causing the hydraulic fluid to push the seal
  sideways and exit through the dust cover.