How to Remove the Clutch Master Cylinder in a '95 Jeep Wrangler

The 1995 Jeep Wrangler was available with a 2.5-liter inline-four or 4.0-liter inline-six cylinder engine. The manual transmission was equipped with a hydraulic clutch system. This system uses a master cylinder on the engine firewall that is connected to the clutch pedal and a slave cylinder mounted on the transmission that actuates the clutch when the pedal is depressed. Hydraulic clutch systems are similar in operation to the vehicle's brake system. The hydraulic clutch system makes it easier to push in the clutch pedal, compared with a mechanical linkage. In 1995, Jeep Wrangler has a unitized clutch system, meaning the master cylinder and slave cylinder must be replaced as a unit. The procedure to remove the clutch master cylinder is the same for either engine.

Instructions

Removal

1

Park the Wrangler on a level, paved surface and set the parking brake. Raise the front of the Wrangler with a jack and support it with jack stands.

2

Move under the transmission and use a ratchet and socket to remove the two nuts that hold the slave cylinder onto the transmission. Disengage the slave cylinder from the transmission at the clutch housing and unclip the hydraulic line from the retaining clips.

3

Remove the bottom mounting nut on the master cylinder from inside the engine compartment with a ratchet and socket. That nut is attached to a stud.

4

Move to the interior and pull the metal clip off the clutch pedal pin. Slide the master cylinder push rod off the pin. Have an assistant unbolt the master cylinder's top bolt with a wrench. Remove the nut with a ratchet and socket from inside the Wrangler. The top master cylinder mount is held on with a nut and bolt.

5

Pull the master cylinder out of the firewall. Lift the master and slave cylinder assembly out of the engine compartment, being careful not to get brake fluid on the paint. If you do, immediately wash it with soap and water.

Installation

6

Lower the master and slave cylinder assembly into the engine compartment. Slide the master cylinder into the firewall and thread on the bottom nut finger tight. Move under the transmission and mount the slave cylinder on the transmission, install the nuts and use a torque wrench to tighten them to 19 foot-pounds. Clip the hydraulic line into the retaining clips.

7

Install the top master cylinder bolt and nut. Torque both of the nuts to 19 foot-pounds. Mount the pushrod onto the clutch pedal and install the metal clip.

8

Don a pair of safety glasses and fill the master cylinder with fresh DOT 3 brake fluid. Fill a plastic water bottle with about 2 inches of fresh brake fluid. Move under the transmission and attach a box-end wrench to the bleeder screw on the slave cylinder. Attach a piece of 3/16-inch clear tubing to the nipple on the bleeder screw. Submerge the other end of the tubing in the brake fluid in the plastic bottle.

9

Instruct an assistant to push the brake pedal down three times and hold it down on the third stroke. Open the bleeder valve by turning it counterclockwise. A gush of air and a little bit of brake fluid should come out. Close the bleeder screw. Tell your assistant to pump the pedal again and hold it down. Open the bleeder screw. Air and more brake fluid will come out this time. Check the fluid level in the master cylinder and refill it. Repeat this process until no air exits the slave cylinder when you open the bleeder. Remove the tubing and plastic bottle.

10

Raise the front of the Wrangler, remove the jack stands and lower it to the ground. Top off the master cylinder and screw on the cap. Check the clutch for proper operation.