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od;
"hi ron and manual trans/clutch sages- this part(internal slave cylinder) is one of the worst automotive designs i have experienced. maybe in a dead heat for last with the interference engine." [Its not a bad design but absolutely common for the era, and typical of probably millions of pass. cars and trucks. The specific implementation by Girling which allows piston to cock and scratch is not the one with ultimate longevity, but they last decently for a long enough service life (not to say that improvements couldn't make that longer, and I've addressed this) ... but what happens after 50 years and who knows how many rebuilds of what quality, you can't make general statements about the design...on the other hand, you can make general statements about china-shit hardware: Bad materials quality, accompanied by bad workmanship...justabout every time!...ask OP!...and whadaya mean "internal slave cylinder"? The piston is internal (kinda has to be that way for Hydraulics to work!), but the Master and Slave Cylinders are External and quite accessible and serviceable?]
"thank god the 240s all seem to have a normal clutch fork and throwout bearing actuated by an external cable. surprised some other models of volvo use this slave cylinder. every one i have seen is prone to early leaks, much sooner than the clutch itself fails." [Whadaja mean by "early leaks"...how many miles, and decades?...those Volvos just don't last...!]
" if i had to do another one (have done 2 in my 01 saturn 100) i would make sure it was american made to maximize longevity. both of them started leaking with about 50k on the car. clutches typically with me last over 100k. this job winds up costing about 1500- 1800 if you hire it out. took the leaking saturn cylinder apart and there was i think 2 shot rubber orings on the scuffed piston." [I can't speak to Saturn's design or implementation, or longevity, but I'm certain it's nowhere near that of the Volvo...I can't remember seeing a Saturn, ANY Saturn, on the road in the last 6 months, and how old would they be now?...looks like they're all already crushed!]
" the clutch pressure tension, vibration and hot environment all work to speed up the demise of the part." [Which is it... pressure or tension? Hydraulic Clutch actuation system uses pressure and pushes throwout linkage, Cable based sys uses Tension and pulls on Throwout linkage...and by the way, when your foot is off the pedal, there is NO pressure OR Tension in either Clutch actuation system!]
"should have kept the cable design or lever(if possible on an fwd). hondas and toyotas use an easy to replace external plunger slave cylinder." [Can't speak to their design either, but how's an "external plunger slave cylinder" work?]
"my apologies, me bad. do have one question - if stuck with a leaking slave cylinder(they give no warning)" [you think a clutch cable does before it blows apart...whatse diff?] "and no go on tobacco road, is there an on the road short cut you can use to get you going? (other than carrying 2 qts of dot3/4 and refilling clutch master every few miles)?" [Clutch Hydr Sys uses less than about a typical pint container of Brake Fluid...they typically loose fluid a drop at a time, so wouldn't piss out that fast when you refill them...I betcha a Volvo driver who looses their Clutch due to no fluid in the reservoir hasn't checked the fluid level in a looong time...and if you don't have any Brake Fluid on-board, you can still make it home, or at least the nearest place where you can get Fluid, by carefully shifting without the Clutch...(done it several times over the decades...even when Clutch was working fine, just to practice!...Love those M40s!)...including once out of necessity, stopping the engine at a Toll Gate, and restarting in gear...
thanks tons oldduke [Your welcome...BTW, do you also exaggerate as much when drinking caffein-free? ...just wondering...and oh yeah...SHIFT key broke?
Cheers
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