then why was this clutch slave cyl wrong?
 

1982 us 5sp build 4/82 .. part fits through 8/82. the rod was half inch too short i did take the old rod and used it on new one. is there something that has moved in the clutch itself ? .... for the euro cars only?

Nope. There are two versions of the clutch master. I bought the wrong one for my '84 Euro and it would not throw the clutch far enough to release completely. Drove me completely berserk for a month's worth of clutch bleeding. (I was convinced that air in the line was the cause of my non-releasing clutch) Had to replace the clutch master a second time to correct the problem. To this day, I 'm not sure if there is another part number or if it was a superceded part or what. I'm just glad I finally got it figured out.

If we are talking about rebuilt parts that could explain a screw up.

No, mine was brand new. Just 2 different throws. The shorter throw would not fully release my clutch.

This has been well documented. The difference is in the clutch master, not the slave.

Here is the thread where it was originally identified as a problem.

thank you for the reconnect with link, i held on to it, but computer crashes later lost. now its my tuwwn again. I fixed the slave once lasting couple more yrs , it couldnt have been any finer, m/c , slc,clutch, pedal, shifter,bled,fluids.

i do a new slave cylinder and dont think its going to be any one thing, sooo bad.

m/c good, needs rod greasing.. check hose
pedal needs a bushing/ lateral walky.. and clutch engaging like half way slammy/clunking/smooth not good as was.
5sp shifter is crap loose, shifts great every gear warm/cold, way too much play now
will make another kind of adj.. bell housing thread?
check 75/90 gear oil.
give a bleed again only really did clutch brake was real fine weakened so will do whole sys.

still dont get if new slave had shorter rod and used old rod(is not just changing out rod good enough?), is it the guts(spring..) in the slave thats different movement?, i didnt touch master cyl so why would that be an issue if the m/c works in the car w the old rod and now ive just got new innerds and new boot.

78/79 9in m/c not sure got to measure m/c 1982 5sp us? thought 10in but in buying new sl cyl it listed through 8/82 fitment and mines 4/82. hmm. well it was def wrong slv cyl, rod had all i could do to get throw as is and the new rod would not even close.

i get how to do the fix write up m/c or slv? but will check and do more ,then will know if got to go this to fix pcar. many crappy things happening all at the same time.