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Is your clutch properly adjusted? If it is adjusted too tight, it might apply too much movement to the slave cylinder causing it to overextend past the seals. I don't know if that is even possible, but it's an idea... What kind of clutch are you using? As for the pathfinder slave, there are a couple of things: Noone (besides you I guess) has trouble with the OEM slave, so why mess with a good thing? Changing the size of the piston in the slave cylinder will have an unintended consequence. Since the master cylinder will still displace the same amount of fluid, it will not move the slave cylinder as far because it will take more fluid to move the cylinder the same distance. This could make the clutch not fully disengage if it is a big enough difference.
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