HELP! Clutch Slave Rod broke INSIDE TRANSMISSION!?

[r4esh]

Okay, heres the deal. The car is an s52 powered e30 m3 that I've been swapping for the past few months and FINALLY got it to run yesterday (wahoo!). It is an s52 with the ZF 5-speed from the e36 m3. We DID have the tranny off the motor to move the clutch and flywheel to the s52. I did NOT touch anything else. I didn't mess with the clutch fork or bearings or anything.

The car originally had an m50 in it (strange why someone put an m50 into an e30 m3 I know). But it had the ZF e36 5 speed on it, so for the swap we just disconnected the clutch slave, left it dangling, swapped the new motor in, and re-connected it (with the intention of not having to re-bleed the clutch). Re-connected the clutch slave no problem, but my clutch pedal was to the floor... it had been a few months of sitting while finishing the rest of the car so we decided to try and bleed it. So we went through the process and half way through we noticed brake fluid leaking from the bell-housing. Removed the clutch slave and the rod had broken. So, got a new one rush-ordered (since this is the only thing keeping me form driving her), put it in. Aligned it to the fork with my finger, but there was resistance trying to push it in. At this point we connected the line before trying to install it. I played with it a bit and I'm not sure what allowed it to slide into place, but it did, so I decided to tighten it up and give it a shot.

Needless to say, during in the bleeding phase we heard a loud "pop" and it broke the slave rod again.... Only this time, when I went to remove the slave... the rod didn't come out with it and is somewhere in the transmission. I tried fishing with a magnet and didn't have any luck....

SO... questions:

1. Any ideas on how to get that "F-er" out without dropping the tranny?
2. Do I have to drop the tranny (ugh!)
3. What the hell am I doing wrong that is causing me to destroy these clutch slaves like this?
4. I tried pushing the clutch fork in with a ratchet extension and could not get it to budge (which is why I'm assuming its breaking the slave rod). Is it seized? Should I be able to feel some play with it?
5. I know there is a little grove that the slave rod is supposed to fit within, do you think I just had it UN-aligned and NOT in the grove?
6. Do I have to put the clutch slave on FIRST and THEN connect the high pressure line???

MY new clutch slave cost me $65 bucks so I'd really not like to blow through another one..... And I'll owe someone mega if they can help me get that slave rod out of the bottom of my tranny....

[r4esh]

I found THIS link explaining others with my same issue of the exploding clutch slave into the tranny, but no one posting back as to why or what the fix was.

[Leo_328i]

I had this happen to me in my E36 328i. Was the single biggest fucking pain in the arse I ever had to deal with.

The only thing you can really try without taking out the transmission is using one of the little holes at the bottom of the transmission to stick one of those bendy flexible magnetic things in - when I tried it it did not work out for me.

I also once dropped one of those 13mm nuts into the hole where the slave cylinder goes and was cursing myself as I thought I needed to remove the transmission again. I actually stuck my fingers (I have very small asian hands) inside the hole and I was lucky that it actually dropped very close to the hole and I very carefully took the nut out. Phew.

I'm sorry to be the bearer of bad news but unfortunately you will almost definitely need to remove the transmission to get that bastard out.

Btw, you will need to get a new clutch slave as well. I tried to put my exploded one back together but couldnt quite get it to go back together either. The slave explodes when the rod is not properly aligned with the clutch lever and it shoots off to the side and 'explodes'.

Next time try and feel when the rod feels like it is pushing against the fork, difficult to explain but you will feel it when you put it on properly. When you've achieved this, then with one hand hold the slave cylinder tight against the tranny with one hand and then quickly grab the nuts and tighten them onto the threads sticking out of the tranny.

Good luck mate - don't feel bad as I've been in your shoes TWICE. Just don't be as daft as me and make the same mistake again!!!

[JdmEuroNorth]

Just take the transmission off?

It shouldn't take more then an hour to take it off and then you can see everything clearly, why it broke, how it broke and you can change it to work better for you.

[N2MYE30]

Just take the transmission off?

It shouldn't take more then an hour to take it off and then you can see everything clearly, why it broke, how it broke and you can change it to work better for you.

Yes, take it out just to make sure alls well. I helped my buddy with this and we would not have know what was goin on if we didnt crack it open. Too much work to fubar something else.

[r4esh]

Well. I got a couple of magnet options. I will head out there today and try and go fishing again. Fingers crossed and wish me luck maybe I'll get lucky and the rod will come out.
Thankfully my local auto store warranted the broken slave and a new one will be here today.
If all else fails I'll drop the tranny. You guys seem pretty optimistic on how long that will take... sounds like a royal pain in the arse to me with the position its in, but you gatta do what you gatta do.
I will report back.

So is the general consensus that I just aligned the clutch slave wrong? OR do you guys think something is wrong with the fork setup?

[Wanganstyle]

Which slave did you order? ZF slave or G260 slave? or G265 e30m slave?

the ZF slave has a long snout, looks funny.

I actually had the pin from slave shoot out into the trans (slave exploded).

easy fix:

Home depot + 2" hole saw bit with self aligning center drill bit. Drill small hole in bellhousing, remove the offending broken items.

leave transmission in car, dont even bother removing it.

How safe is this? Proven by many track guys as they cut a "access" hole or clutch inspection hole in bellhousings often.

I ran a S54b32 with over 300rwhp with my 5 speed "holy bellhousing" trans. bellhousing was a happy snail even with a 2" round hole cut out, like those lab cows @ university's with study ports in stomach.

[r4esh]

lol at "wanganstyle".... A buddy of mine suggested this method as well... I don't love the idea... but I guess its an option...

I just got done with work and am heading out there to see what I can do. I will report back.

P.s. - I am using the proper clutch slave for the e36 ZF tranny.

[JdmEuroNorth]

separate driveshafts, undo transmisson mount, tilt engine back (it'll do this by it's self)removed line to slave cylinder, Use a long extension with a ratchet to undo the bolts. Take the tranny off and see what kind of damage has been done.

If you just go fishing and you get one piece out and the rod actually broke it 2, you're doing some damage and I'm sure that parts store won't warrenty it twice.

[nrubenstein]

i fished one out with a magnet. That said, if you're killing slace cylinders like that, i have to wonder if there is another issue.

[325issguy]

Mine was doing this when I had my throwout bearing installed incorrectly. Pull the trans and make sure everything in installed correctly....

[r4esh]

SOLVED! : Okay so I WAS able to fish it out by using a magnet through the slave hole. And it came out intact and all in one piece. Yay! So I took my chances and installed the NEW clutch slave... this time being VERY careful that it was on the clutch fork inside. There was a LOT of resistance, so I knew it was where it needed to be. I had to really push on it to get it far enough over the nuts to start tightening them. Anyway.. bled the system and it did not bust! Finally I got to drive my much anticipated s52 swapped e30 m3 and was very pleased with the power!
Ultimately I think the issue was the lack of room to work down there and I must have installed the other ones at an angle where the slave rod missed the clutch fork altogether, then as it built pressure it had nothing to press against and thus torpedoed that sucker into the bell-housing (doh!). Thanks all. And cheers / goodluck if this happens to someone else.

[Wanganstyle]

lol at "wanganstyle".... A buddy of mine suggested this method as well... I don't love the idea... but I guess its an option...

I just got done with work and am heading out there to see what I can do. I will report back.

its actually a reasonably common track car action in all sorts of cars. very easy to check your clutch wear if you have a access hole!!!

[6gen91]

its one of those things "do it while its out of the car" , think ahead my friend