We got the clutch in the puller today and it disengaged nice once. Then oil came pouring out of the bellhousing and no more dis-engagement.

The slave fell apart upon removal. It looks like there was a steel inner sleeve that came out.

Anybody ever had this happen? Is it just toast?

 

That same thing happened to me half way to my place in Mexico, in Nogales. Fortunately, All of the parts were still there and there was a wallmart close, so I bought some jb weld and glued it all together. The cap that the rod goes through was half way off, but still stuck on or it would have been an expensive tow back to Phoenix. That was in 2005 or 2006 and I am still driving on the same repair. I bought a new clutch master cylinder and slave and it lives in my tool box, if it ever goes again...Mark

 

By the looks of it, yes, the slave is toast.
I assume you maybe didn't compare the total clutch heights between the stock and aftermarket clutch?

There's 3 notches to hold a round wire clip that retains the plunger assembly.
In the 2nd pic it looks like at least 2 of those 3 notches got ripped out.

That tells me that the piston assembly over-extended and you pushed the guts out, OR the hydros weren't installed correctly and something slipped causing failure.

Over-extension is probably the culprit here, especially since your using aftermarket clutch pieces, which may have a shorter cumulative height than the stockers, causing the slave to push further down the bore.
The fix for that is to make a longer slave pushrod and re-use your plastic pushrod cap.

Another thing that COULD have happened to cause the over-extension, is that the plastic pushrod cap broke on application and the pushrod slid that much further.

Mark.

 

Good eye Mark. After I looked it over sat. morning I saw the broken tabs and found the circular clip on the floor. I really don't think it is a clutch issue, it is all 2nd gen now. Except the slave and rod. Wich I was thinking was the same.

I am thinking the petal must have got pushed down accidentally.

I have a plan to fix it. I will wait to see if it works and report back.

 

Well with some old fashioned rigging we got it fixed. Put the clip back in, and a 1/2" hard flat washer just just happens to snap down inside it. Preventing the clip from compressing and coming out. Followed it up with 1/16" retaining pins, and its good to go.

Disengages just fine now.

 

Looks like it will work fine, but if you really needed one, all you had to do was ask.

Mark.