Finally got around to installing a new slave cylinder (old one was creaking). Macgyverd up a jig to keep the cylinder compressed, removed the old one and installed the new one (FTE exactly the same as I removed). Just as most instructions say, I made sure the hydraulic line still had the o-ring installed.

The problem I have is when I try to bleed it (2 man .... actually one man and one impatient wife) the hydraulic line keeps popping out and spewing brake fluid (to the tune of 1 bottle thus far). Did I get a defective slave cylinder (the little metal clip doesn't feel that solid) or am I bleeding it wrong? I open up the bleed screw (while it is still compressed), ask the wife to push the pedal down close the screw and aske her to bring it back up again. After a few times of this the pedal starts to feel more solid and that"s when it pops. Any help would be very much appreciated.

 

If the line is popping out of the slave cylinder the retaining clip isn't doing its job. Either not engaging the ring land, or is bent enough that it isn't able to properly retain the slave.

The O-ring is on the line, correct? Not stuck in the slave and then the slave installed on the line?

If the O-ring is cocked in the bore it could be causing undue pressure buildup and not allowing the fluid to flow and the clip just so happens to be the weakest link.

 

You have the cylinder compressed correct? You may need to compress the slave cylinder fully in order to bleed it. We have a tech article with details images that cover this job. Not sure if it'll help, but maybe check it out and see if it may help you with your situation. It goes over, in detail, the bleeding process.

http://www.pelicanparts.com/Mini/index-SC.htm click on "tech info" tab at the top, scroll down to Transmission & Axles and click on Clutch Master and Slave Cylinder Replacement.

 

Thanks for the responses, much appreciated. I think the clip is the problem. Filed a warranty claim and expecting a new slave cylinder soon.

 

I agree the clip is a factor. I'm creating a clamp that will sandwich under the housing and the top of the hydraulic fitting above the clip. Please let me know if your warranty claim yielded any positive outcomes.