Tools You'll Need:
* New Clutch Master Cylinder: Ensure you get the correct part for your Jeep.
* Wrench Set: Metric and possibly SAE depending on your Jeep's configuration.
* Socket Set: Metric and possibly SAE.
* Open-End Wrenches: Useful for tight spaces.
* Screwdrivers: Phillips and flathead.
* Pliers: Needle-nose pliers can be helpful.
* Brake Cleaner: To clean the area and components.
* Shop Rags or Paper Towels: For cleaning.
* Container: To catch brake fluid.
* New Clutch Line Bleeder Screw (optional but recommended): It's prone to damage during removal.
* Torque Wrench: Essential for proper tightening of bolts.
* Clutch Bleeder Kit: To bleed the clutch system after installation.
Procedure:
1. Safety First: Disconnect the negative battery terminal.
2. Prepare the Area: Work in a well-lit, clean area. Have a container ready to catch the brake fluid that will drain from the system.
3. Access the Master Cylinder: The clutch master cylinder is typically located on the firewall, usually near the brake booster. You may need to remove some components to gain access, such as the air intake or other parts depending on your specific model. Consult your repair manual.
4. Disconnect the Clutch Line: Carefully loosen and remove the brake line from the master cylinder. It's a good idea to replace the bleeder screw at this point. Have your container ready to catch the fluid.
5. Disconnect the Master Cylinder: Carefully remove the bolts securing the master cylinder to the firewall. Note the location and orientation of any brackets or components connected to the master cylinder.
6. Remove the Master Cylinder: Once the bolts are removed, carefully pull the master cylinder away from the firewall. There may be some resistance due to the rubber boot or other seals.
7. Clean the Mounting Area: Thoroughly clean the mounting area on the firewall with brake cleaner to remove any dirt or debris.
8. Install the New Master Cylinder: Carefully install the new master cylinder, ensuring that it is seated properly and aligned with the mounting holes. Install the bolts and tighten them to the manufacturer's specified torque. Don't over-tighten!
9. Reconnect the Clutch Line: Reconnect the clutch line to the new master cylinder, ensuring a tight and secure connection. If you replaced the bleeder screw, be sure to tighten it appropriately.
10. Bleed the Clutch System: This is crucial. Use a clutch bleeder kit to carefully bleed the air from the clutch system. This typically involves opening the bleeder valve on the slave cylinder (located at the transmission) and pumping the clutch pedal repeatedly while keeping the bleeder valve open to allow air to escape. Consult your repair manual for the proper bleeding procedure.
11. Test the Clutch: Once the system is bled, start the engine and test the clutch operation. The clutch pedal should feel firm and engage smoothly.
12. Reconnect Battery: Reconnect the negative battery terminal.
Important Notes:
* Brake Fluid is Corrosive: Handle brake fluid carefully and avoid getting it on your skin or painted surfaces.
* Air in the System: Air in the clutch hydraulic system will result in a spongy or unresponsive clutch pedal. Proper bleeding is essential.
* Repair Manual: Using a repair manual specific to your 1991 Jeep Wrangler is strongly recommended. It will provide detailed instructions, diagrams, and torque specifications.
This is a general guide. Improper installation can lead to clutch failure or damage to other components. If you are not comfortable performing this repair yourself, it's best to consult a qualified mechanic.
