Tools You'll Likely Need:
* Socket set (metric): Various sizes, including those for the slave cylinder bolts and brake bleed nipple.
* Wrench set (metric): For potential line wrenching.
* Clutch alignment tool: Crucial for reinstalling the clutch properly. This is a specialized tool; renting is often an option.
* Brake fluid: DOT 3 or DOT 4, as specified in your owner's manual.
* Clear tubing and container: For bleeding the clutch system.
* Jack and jack stands: Essential for safe working conditions.
* Wheel chocks: For added safety.
* Gloves: To keep your hands clean.
* Rags or shop towels: To clean up spills.
* Penetrating lubricant (like PB Blaster): To help loosen rusted bolts.
Procedure:
1. Safety First: Disconnect the negative battery cable. Use jack stands to securely lift the vehicle and ensure it's stable. Engage the parking brake and use wheel chocks.
2. Access the Slave Cylinder: The slave cylinder is located on the transmission, usually near the bellhousing. You'll likely need to remove some components to gain access. This might include:
* Removing the tire and possibly the splash shield: For better access.
* Possibly removing parts of the exhaust system: Depending on your Comanche's configuration, some exhaust components might be in the way. This could require additional tools and patience.
3. Disconnect the Clutch Line: Use a wrench to carefully loosen the brake line fitting connected to the slave cylinder. Have a rag ready to catch any spilled brake fluid. Be prepared for some fluid to escape; it's not a large amount but you should catch it.
4. Remove the Slave Cylinder: Unscrew the bolts holding the slave cylinder to the transmission. Penetrating lubricant may be necessary if the bolts are seized.
5. Install the New Slave Cylinder: Before installing the new slave cylinder, ensure the clutch fork is properly positioned. This often requires using the clutch alignment tool. Carefully install the new slave cylinder, ensuring it's seated correctly and bolted in tightly. Don't overtighten!
6. Reconnect the Clutch Line: Carefully reconnect the brake line to the new slave cylinder.
7. Bleed the Clutch System: This is crucial to remove air from the system. You'll likely need a helper for this step. The method varies slightly depending on your vehicle's specifics but typically involves using a wrench on the bleeder valve located near the clutch master cylinder (inside the cabin) while your helper pumps the clutch pedal. Be sure to consult your repair manual to see your vehicle's system for bleeding. This process involves opening the bleeder screw, having the helper pump the clutch pedal multiple times and holding the pedal depressed while closing the bleeder screw, and repeating this until no more air bubbles appear in the clear hose.
8. Reassemble: Reinstall any components you removed to access the slave cylinder.
9. Test: Lower the vehicle, reconnect the battery, and test the clutch operation. Make sure the clutch pedal feels firm and engages properly. If you have any issues, re-check the bleeding process.
Important Considerations:
* Brake fluid is corrosive: Wear gloves and be careful not to get it on your paint.
* If you're uncomfortable with any part of this process, take it to a qualified mechanic. This is not a simple job for the inexperienced.
* A repair manual specific to your 1989 Jeep Comanche is strongly recommended. It will provide detailed diagrams, torque specifications, and other important information.
This is a general guide; the specific steps may vary slightly depending on your vehicle's condition and modifications. Always prioritize safety and refer to a repair manual for accurate and detailed instructions.
