clutch master hassles

[Mike Arman <armanmik@n-jcenter.com>]

(86 5KS)

About a month ago, I started having trouble with the clutch action not being
correct. On advice, I rebuilt the clutch master cylinder and it was fixed.
The kit cost a whole $10.59 at Discount Auto Parts (Wagner components), and
other than standing on my head in the usual haze of brake fluid, the job
wasn't notably nasty.

Last Thursday, had to go to Orlando, clutch problem recurred one minute
after I left the office. 100 mile round trip, downtown and rush hour
traffic, hadda go, held my breath and suprise, I made it - no failure,
clutch action very poor.

Now here's the strange part: I originally rebuilt a spare MC from my parts
car, and just swapped it for the original which failed a month ago. I now
rebuilt the original master cylinder, swapped it back and tried to bleed it,
no good at all!

Clutch would NOT disengage, no resistance to pedal, fluid level in resevoir
not dropping! Remove, disassemble, inspect, no problems, reassemble,
reinstall, no results. @!**?%

Bought a THIRD kit (glad they're cheap), rebuilt MC from parts car (again),
installed, worked perfectly for three days, now showing preliminary signs of
flakiness - sometimes pedal won't come all the way back, sometimes works
perfectly.

I think I found out why the original MC won't draw: Plastic spigot on
original car MC is black, replacement is white, length of end of white
spigot that plugs into MC (feeds from brake resevoir) is just a little too
long, and blocks the inlet port - only reasonable (?) explanation of total
instant failure of original M/C.

Now - when I took apart the replacement M/C, the secondary (top) seal looked
dry and scuffed, not slippery with brake fluid. Ideas? (this is now in the
car, acting strange, rebuilt for second time)

I'm going to do the slave next, but not looking forward to it. Can I avoid this?

Chronology:

Original M/C failed, rebuilt parts car M/C, installed, worked 1 month,
failed with scuffed seals

Original M/C rebuilt twice, refused to work both times.

Parts car M/C rebuilt second time, worked 3 days, showing preliminary signs
of failure.

Yes, I gently honed the bore, and used clean brake fluid and a tiny touch of
Castrol rubber grease to assemble. (Eases the secondary seal over the spindle.)


Thoughts?

Best Regards,

Mike Arman