1998 Rodeo, 3.2, 2wd, 5 speed, 102k miles, clutch fluid changed and bled at ~75k

the past few mornings, my clutch seemed to be slipping (or not engaging normally) when accelerating from stop in first gear. there was also a little bump or two going from first to second. after driving 15 miles or so, things seemed back to normal with smooth clutch engagement. same thing coming home from work in the evening.

i checked the master cylinder last night and it was nearly empty. there was no sign of leakage from the master all the way down to the slave. i flushed and bled the system and everything was back to normal...until this morning. same problem, just not as bad.

i went ahead and removed the slave to look for leakage internally. the boot and push rod were covered in grime. the bell housing had a little too. i pushed the slave piston assembly in and a little fluid and few tiny bubbles came out. i repeatedly pushed the piston in and out till there were no bubbles, put the slave back on and took a test drive. back to normal.

i assume replacing the slave will solve my problem. should i remove the master and clean it while i'm at it? anything else i should do other that replace fluid, bleed, and re-adjust the pedal?

If you are noticing leakage, the slave sounds like the culprit. I would leave the master alone until it fails - on my 1988 Trooper, it is a much bigger job to repair the master (as it is on most vehicles) so I won't touch it unless I have to.

As an aside, you can often save money by buying a rebuild kit for the slave (or master) and installing that instead of replacing the entire unit. Most non-chain auto suppliers stock them, as do many brake parts suppliers. Look for a warehouse with a city desk - go where the garages go to get parts.

Rebuilding is usually very easy - I have never had a scored cylinder bore, and all I have to do is pull the old innards out and put the new ones in. Generally involves no more than removing a circlip and cleaning the cylinder before reassembly. Lube it with some clean brake fluid before installing the new plunger and you're set. Should save you at least $20.

Man, I should not have responded! Not a day later, my (2-year-old) slave cylinder went south. Oh well... bad luck.

I replaced my slave twice at about 75,000 mile intervals, which isn't too bad, for the third I replaced Master, slave, and all in between. I now bleed it "a lot."

1998 Rodeo, 3.2, 2wd, 5 speed, 102210 miles, slave cylinder and clutch fluid changed and bled two weeks ago

so i went ahead and changed the slave cylinder and bleed via vacuum. things seemed better after first test drive. later that day, i went to the grocery store and when shifting from first to second the clutch stayed on the floor and the clutch slammed engaged. i limped to a parking lot, went and got my tools and removed the slave to find the push rod had fallen out of the cup on the fork. i just put it back thinking maybe i did not stab it right the first time. drove fine for two weeks.

same thing happened again at the busiest intersection on my way home today. this time it happened when pulling away in first. i left in first and started to get out of the intersection. same thing, push rod out of the cup.

could this be the throw out bearing hanging up when i let the clutch out? this would allow the push rod to fall out of the cup. then when the throw out bearing frees up, it would slam the clutch engaged with the rod dangling and clutch stuck on the floor. any other ideas?

update: of the three times i installed the slave, i never had the rod completely inserted. got it all the way in and had to top off the master as expected. everything feels good now. cross your fingers for me.