The piston is made out aluminum and has worn out. I't got so short it almost fell in the bell housing. We have a Machine shop were I work at. They can copy it at no cost. There is nothing wrong with the slave cylinder.
Have you ever replaced it on a 240d? I ask because I did, and it was an education. You need to reverse bleed the system, forcing the brake fluid through the top, down through the clutch slave and out the bleeder -- and do it a bunch of times to get every air bubble out.
If you need any help with how I did this I'm happy to help -- it was truly a couple weeks of working on it and trial and error.
I bled mine like you would bleed brakes. Pump it up, hold the pedal down, crack the slave bleeder, close bleeder, repeat. Worked perfectly and I have not had any problems in over a year.
You are very lucky! I replaced both the master and slave. Tried to bleed it myself, no go, then brought it to a Mercedes shop, and it was pretty good. Then I tried to make it better and instead made it worse. Then I did the reverse bleeding and now it's great. I think if you replace both cylinders is where you can get into trouble.
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