Clutch master cylinder replacement - Defender Source
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  #1  
Old May 9th, 2005, 10:41 AM
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Tony Fannin
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Clutch master cylinder replacement

Well, looks like my clutch master cylinder has decided to start leaking. I started getting oil under the clutch pedal this morning. Just a few drops but it's defintely clutch fluid. I know this is a pain to replace and takes a bit of time. My question is: How long do I have to get around to replacing/rebuilding it? I'm supposed to go to the SCARR rally this weekend and there's no way in hell I have the time to do it before then. Will it be okay to wait until after the rally?
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  #2  
Old May 9th, 2005, 10:50 AM
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Mine lasted a while leaking slowly maybe a month or so, but CLEAN up any that leaks out or it will eat your paint!
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  #3  
Old May 9th, 2005, 10:59 AM
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Robert Ragland
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I thought fluid on the floor meant the slave cylinder? Keep a bottle of it in your truck. Nothing worse than being stuck for lack of fluid.
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  #4  
Old May 9th, 2005, 11:01 AM
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Yousef Hamzeh
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Quote:
Originally Posted by Mike Hippert
but CLEAN up any that leaks out or it will eat your paint!


That, and keep it full all the time. You should be ok for this weekend

The slave is under the truck on the left hand of the transmission.
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  #5  
Old May 9th, 2005, 02:53 PM
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I'll bring my old one to SCARR. It was leaking a little when I replaced it and I've been meaning to rebuild it, but it could still get you home if you get in a jam.

Brian
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  #6  
Old May 9th, 2005, 03:10 PM
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Tony Fannin
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Quote:
Originally Posted by d901560
I'll bring my old one to SCARR. It was leaking a little when I replaced it and I've been meaning to rebuild it, but it could still get you home if you get in a jam.
That'd be sweet. If it decided to go while we're there then I'd have a handy replacement to buy from you. Thanks. If it survives the weekend, as I'm sure it will, driving home without a replacement won't be a problem. I'll only have to shift gears like 10 times the entire trip home. The slave went last year nd I knew that folks say to replace both at once but I looked at what needed to be done to do the master and got lazy. My motto of 'Hard work pays of eventually, laziness pays off right now' came back and bit me.

Ok, so let's say I order up a rebuild kit today and have it shipped overnight. Is doing this thing in a evening or so possible?
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  #7  
Old May 9th, 2005, 05:24 PM
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Well maybe if you work fast, but it's kinda a PITA to get it in and out, like playing twister, but instead of it being twisted up with hot chicks you have your hand wrapped around a slippery master cylinder trying to work it out of the firewall and through a bunch of wires, hoses and the break master cylinder. Oh and take the hood off, it helps allot!
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  #8  
Old May 9th, 2005, 08:21 PM
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Mine was leaking slowly for about 2 months before I replaced it two weeks ago. When I started to notice a difference in the clutch, I finally replaced it. I think you should be okay for a little while.
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  #9  
Old May 9th, 2005, 11:26 PM
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Tony Fannin
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Thanks, guys. I think I'll put it off until after the rally then. If things go south while I'm there, Brian said he'd bring an old one just in case. I'll drop the bleed kit and extra fluid on board if I do have to do a field replacement.
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  #10  
Old May 10th, 2005, 07:54 AM
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It's the biggest pain in the ass to replace... ... But I'm no mechanic. In any case, don't let it go too long, because mine leaked for a few weeks and I ruined a few pairs of shoes, namely a nice pair of Johnston & Murphy Penny Loafers... which I really liked. AND when the fluid leaked on the floor it ate up the 'Herculiner' stuff I had put there... Brake fluid is no joke...lol.
And Mike is right... It's really a game of 'Twister' getting that S.O.B. out.

I know it's been discussed on the board, (if a search is done) to just get a new one, don't put someone's used cylinder for this job. Just my .02 cents, but what is it $150 ?

Here's a good link to the forum:
http://www.defendersource.com/forum/...=clutch+master

Oh, and make sure to use Castrol LMA or GT LMA brake fluid.

Nicholas
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  #11  
Old May 10th, 2005, 10:34 AM
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I rebuilt mine without any problem. If you have the patience to remove the old master cylinder the rebuild is nothing. Just be sure the wall of the cylinder is smooth.

I agree emphaticaly with the Castrol GT LMA fluid. I had used another type of fluid in mine and when I rebuilt it, it had lots of black slime in the bottom of the master cylinder. I suspect it was dissovled rubber seals.
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  #12  
Old May 21st, 2005, 09:11 PM
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I did the rebuild of the clutch master cylinder today. I followed the great write up by Ryan in this thread. I didn't go so far as removing the brake master cylinder or anything.

What I did do:
Removed the bonnet.

Loosened the four bolts in pic 1.

unclipped brake lines in pic 2.

disconnected brake springs in pic 3.

removed 6 bolts and spring in pic 4

pulled clutch pedal up a bit and cut a notch in the bulkhead shown in pic 5.

Cutting that notch made life much, much easier. The pedal and master cylinder came out quite easily. In the future I'll be able to pull the whole thing in 1/2 the time it normally takes.
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  #13  
Old July 4th, 2015, 06:07 PM
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Have looked at this 100 times, cut the notch, but absolutely cannot fish out the MC housing. Any tips?!
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  #14  
Old July 4th, 2015, 06:44 PM
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I changed mine without maiming anything.
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  #15  
Old July 4th, 2015, 06:48 PM
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Did you remove the entire pedal assembly without removing anything else?!
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  #16  
Old July 4th, 2015, 07:03 PM
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Removed the brake MC bolts and moved it to the side then wiggled it out.
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  #17  
Old July 5th, 2015, 08:42 AM
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No need to notch anything. I've done this a few times and I've only needed to remove the hood to gain enough access to twist the pedal box and clear the bulkhead
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  #18  
Old July 5th, 2015, 08:59 AM
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I removed the DS fender skin. Plenty of room, even enough to place my coffee and donut...
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  #19  
Old July 8th, 2015, 11:51 AM
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Quote:
Originally Posted by javelinadave View Post
I changed mine without maiming anything.
Correct...me also.....wiggled it out and replaced....always replace with original master cylinder and never aftermarket IMHO.




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  #20  
Old July 8th, 2015, 12:05 PM
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Quote:
Originally Posted by Ohlins View Post
always replace with original master cylinder and never aftermarket IMHO.




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^^^^^^^This too!^^^^^^^
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