Check your Clutch slave-cylinder boots !!!

[revnkev]

Have just repaired my siezed clutch slave cylinder,
stopped at the lights,depressed the clutch and when
I went to go the peddle stayed on the floor
got underneath with a big screwdriver & hammer and
could'nt budge it once I got it towed home and removed
the slave cylinder we found the cause of the problem.
The rubber boot on the slave cylinder had split where the
push rod exits (which is facing forward ) and collected muddy
water, which the boot held in the end of the cast iron bore and
corroded it. So when the aluminium piston contacted the rough
end bit it stuck in the open position.
So learn from my mistake,
"Keep a check on your boots"
cause if this had happened in the bush it would have been a real PITA.
Also " Don't stand on the clutch peddle " ,as you'll bend the push rod
that engages the master cylinder which has some stupid plastic washer
holding part of the assembly together which means you have to
remove the master cylinder to fix it
Chow 4 now,
Kev.

[Spimon_NH]

if this had happened in the bush it would have been a real PITA.

Sure was! Happened to me 600k's from home (the seal was corroded tho, not from mud). Found a slave cylinder at the local wrecker, which was also screwed . Ended up taking the pushrod out and driving home with no clutch. Actually wasn't too bad once we got going and I got the rythm of changing gears with no clutch under control. Fun times.

[Bitsamissin]

Yes this happened to me last Xmas on a trip to the High Country.
Going up a VERY steep track at the start of our trip and went to change into 1st = clutch went to the floor and wouldn't come back.
The rubber piston seal had disintegrated so it wouldn't hold pressure.
We found that the piston out of a Hilux slave cylinder fitted - just (mate had a spare one) and that got me going and allowed me to continue. There's about 0.5mm difference in bore size so if the Mitsi one is worn the Tojo one fits but it's tight.
Interestingly the Tojo slave cylinder piston runs a double seal where as the Mitsi one is only a single seal.
I replaced it with a new PBR unit $70 and carry the old one with the Tojo internals as a spare. You can also buy the PBR piston/seal kit for the Mitsu one for about $15 (good to carry as a spare).
Another trick is to wrap a bit of cloth around your old piston if the seal has perished usually this is enough to get you home.