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QUESTION: Anybody else get leaks while pressure-bleeding a home-rebuild immediately after installation which then STOP COMPLETELY with a few pedal strokes?
HISTORY: Slave on my '88 900T is not a year old, master even younger than that. Put new seals in it just a couple months ago as linked below, but middle of June it started leaking down empty overnight; a week later it wouldn't even hold pressure long enough to leave the driveway.
So I tore it all open and popped the slave apart. O-rings didn't *look* damaged, although there was fluid everywhere outside the PP. Slave sealing surfaces showed very little very light wear from metal-on-metal contact, probably *outside* the o-rings' stroke. But I hand-buffed the surfaces a bit with a finely abrasive pad without removing any significant amount of material: I can still see the worn spots as well as the factory machining marks, I just can't find them by touch now.
So then it all went back together, clean-room style other than wet seals/grooves, but with the clutch cover off to see if it was going to hold anything: Released PP fingers and spacer with 3 Fat Nuts and then pressure-bled from the slave back to the reservoir before pushing the pedal. The feel SUCKED: All erratic, inconsistent resistance like the line was still full of air and Oh Look, fresh rivers of fluid running down from the slave. I was assuming the slave itself was somehow un-rebuildable but my supply of profanities was already exhausted, and I re-bled and slowly pumped the pedal a couple more times, more out of denial than anything else considering I could see leaks pulsing with strokes of the pressure bleeder... but then on one pedal stroke it held. Repeatedly. So I hosed out the housing with brake cleaner to get a dry surface and kept working it to look for fresh fluid leaking. I even snipped slits in the bottom of the rubber bellows/boot to release any fluid coming out inside of it... NOTHING, and the pedal was rock-solid. Reassembled everything else I could while repeatedly testing the pedal for awhile, but it was all still bone-dry when I finally put the cover on. Shifting felt weird when I drove it, clutch grabs later in the release stroke than I'm used to, and... it was fine this morning as well.
SO. All the initial leaky weirdness: Does That Happen on a viable rebuild, or am I gambling every time I leave home like this? I have AAA and a virgin OEM slave on hand now as backup so I will gamble, but I'm also just trying to understand the rebuilding of these parts... Any voices of experience to put this in perspective?
posted by 98.90.132...
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