95 YJ 2.5l Clutch master and slave cylinder install??? - Jeep Wrangler Forum
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Old 08-18-2012, 02:30 PM   #1
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95 YJ 2.5l Clutch master and slave cylinder install???

First off, I'm glad to finally be a jeep owner. Just bought my 95YJ last week and has 114k miles. Everything works as it should besides my clutch.
I've been looking around and it seems it's the clutch master and slave cylinder, which I've found the pre-bled assembly from rockauto (any suggestions other than that?) I'd like to know if anyone can help with the process of the install so that I don't have to spend $500 at a shop.

Issue: Clutch gets stuck mostly when car is warm. Today worst than ever 95 degrees here in miami and with all the red lights I had to turn the car off put it in gear then turn on in order for it to work. Hard to shift to second as well. Any advices would be greatly appreciated. I'm by no means no pro mechanic but have a few friends that can help if needed (toyota techs).

Thanks for all the help.
Charles

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Old 08-18-2012, 04:17 PM   #2
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Charles, buy a jeep manual, either Chilton or Haynes. They go into exquisite detail about changing out a clutch. I am not sure if you have an internal hydraulic throwout bearing or external. Either way, the manual will help.

Tips:

(1) When you finally start taking down the tranny, remove the transfer case first. Be careful because it is not a "balanced unit" and it will be heavy on one end. A friend can be a big help here.

(2) When you remove the bolts holding the bell housing to the engine, put them aside IN ORDER so you know exactly which bolt goes to what hole. On my 1992 YJ, with the 2.5, I had more than four different length bolts on that thing.

(3) Check if the flywheel needs "resurfacing" and get it done. A trick to remove the flywheel bolts is to use a short length of chain to keep the flywheel from turning while you are loosening the bolts. Attach the chain to the flywheel and a convenient bolt on the rear/side of the engine. It works.

(4) Be careful with the clutch hydraulic line disconnect. Sometimes they can be a real pain. If have problems, consider getting a new unit at a Jeep parts website. I found it very helpful, when mine seized up.

(5) When installing the transmission, try getting some long studs to match up two of your bell housing/engine bolts. Let that be your guide to installing your transmission. Once the tranny is on those two studs, she should just pop in to the pilot bushing.

I hope this helps. BUY THE MANUAL.

Take care,

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Old 08-19-2012, 07:36 AM   #3
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The $500 is worth it IMO. I just did this in my YJ and it was a PITA. I snapped both of the shifter handles off when I tried to remove them. Had to disconnect the exhaust at the manifold due to the pipe crossing under the bell housing. Had to buy a bearing puller to replace the pilot bearing at the end of the crank. And that tranny and transfer case are heavy!!!
I went ahead and replaced all my fluids and the tail shaft seal while I had it out along with all my U joints in both drive shafts.
1SAS tips are good information. You will need a transmission or motorcycle jack and at least 1 more good floor jack to do it your self.
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