[Mike Bartlett]

Sal,
I have gone through 2 master cylinders and one slave and it still isn't right. When I rebuilt my master the 2nd time, the 1st time I got a brand new master form SAI, I noticed the internl spring was bent about 45 deg. My theory now is that the rod going from the pedal to the master is too long and when I push in the pedal I am jamming the internal piston return spring so far down in the bore that it is bending it. Then the spring pushes the piston back up the bore at an angle and wears it out. Both times I have rebuilt mine the fluid had tiny aluminum particles in it and you could see one side of the internal piston had been rubbing the bore.

Another thing I noticed was that when I received my new master from SAI the rod, pedal to cylinder, was shorter then my original. At the time I couln't seem to get the shorter rod to disengage the clutch properly but now I am thinking maybe I should have tried harder. I may not have bled it entirely?

Mike