Replacing Master Cylinder - JeepForum.com

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post #1 of 79 Old 01-30-2012, 10:36 PM Thread Starter
cstone94
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1995 YJ Wrangler 
 
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Replacing Master Cylinder

This is going to be a thread of my adventure in replacing my master cylinder in my 1995 YJ 2.5 with 204,xxx miles. I bought the Jeep and noticed an area where it looked like, water, or some type of fluid leaking onto the drivers side floorboard. It wasn't water.

Here's a picture of the spot, and the small rust hole it created:

Here you can see where it's leaking at the firewall (Notice the lovely corrosion):


I replaced the clutch about 5 months ago, and it started to get a little soft about 2 weeks ago, then it finally hit the floor, no resistance. Checked the master cylinder, no fluid, topped it off, still nothing, so I guess air got in the line. I let it sit for a while, and kind of forgot about it. Tonight I decided to go grab the part, and get started.

I started by disconnecting the cotter pin, and moving the plastic rod from the pedal.


Then I started to undo the nuts on the inside of the engine bay, near the reservoir.

After fighting to get to the pesky things, It came off.


Comparison (Old vs New):

I have a few questions. Notice in the next to last picture. How do I get the line off of the master cylinder housing? Is there a special tool?

Any tips for this would be great and if anyone has any questions for conquering this I'd love to help.

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post #2 of 79 Old 02-01-2012, 07:53 AM Thread Starter
cstone94
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anyone know how to get the line off the housing in the next to last picture?

95' YJ - Warn Bumpers/Tire Carrier/Winch - 2.5L - 6" Skyjacker Suspension Lift - 4.10's - Locrite Locker - Dana 35/30 - 35" BFGoodrich KM2's

11' F250 - DD

1982 Toyota Pick-Up - Spray-On Yellow Rhino Lined - Chevrolet 305 H.O. - SM465 - NP208C - All-Pro Off Road 5" Springs - 35x15.50x15 Super Swampers
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post #3 of 79 Old 02-01-2012, 08:21 AM
bigbossd1030
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That hose is held in with a rollpin. Push or drill out the pin pull the hose out and replace the o ring. If you drill the pin replace it too. Be carefull not to use a bit that is larger than the pin. You take the risk of damaging the hose inlet.

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post #4 of 79 Old 02-01-2012, 11:40 AM
jeepjerryp7m8
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Yep a roll pin holds that fitting in. I wouldn't drill it (your choice) just use a proper sized punch and tap it out. Your new M/C should have come with a new pin and O ring.
Jerry
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post #5 of 79 Old 02-01-2012, 12:16 PM Thread Starter
cstone94
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I don't have taps, any alternate?

95' YJ - Warn Bumpers/Tire Carrier/Winch - 2.5L - 6" Skyjacker Suspension Lift - 4.10's - Locrite Locker - Dana 35/30 - 35" BFGoodrich KM2's

11' F250 - DD

1982 Toyota Pick-Up - Spray-On Yellow Rhino Lined - Chevrolet 305 H.O. - SM465 - NP208C - All-Pro Off Road 5" Springs - 35x15.50x15 Super Swampers
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post #6 of 79 Old 02-01-2012, 12:17 PM
pasinbuy
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When he said tap it out he meant to tap on it to get the pin out. You should of disconnect the line before removing the MC. So be careful not to break anything.

Make sure that you bench bleed the new MC.
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post #7 of 79 Old 02-01-2012, 12:21 PM
lukeh
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Quote:
Originally Posted by cstone94
I don't have taps, any alternate?
A small flat head screwdriver, they slide right out. You want to push it from the drivers side toward the passenger side. Preferably before you unbolt the mc from the tub.
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post #8 of 79 Old 02-01-2012, 12:40 PM
jeepjerryp7m8
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Oh, and start the new pin in the new M/C while it is on the bench, much easier than trying while mounted on the Jeep. When you drop the pin (and you will) it will be gone forever.
Hold the pin in a needle nose pliers with one hand and a punch with the other hand and lightly tap the pin almost half way into the hole (use your third hand for this). Mount M/C to firewall insert fitting with new O ring then drive pin the rest of the way.
Should have added, first walk to the hardware store with new roll pin in hand and buy a couple extra, I have found that using the same diameter and a little longer makes life MUCH easier.
Jerry
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post #9 of 79 Old 02-01-2012, 02:25 PM Thread Starter
cstone94
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What do you mean by bench bleed? I got the mc off, got the pin out replaced o ring, inserted line, put.in pin, tightened it back, filled it up, waited for fluid to leak from slave bleed hole. Put the screw in. No pressure at the pedal.

95' YJ - Warn Bumpers/Tire Carrier/Winch - 2.5L - 6" Skyjacker Suspension Lift - 4.10's - Locrite Locker - Dana 35/30 - 35" BFGoodrich KM2's

11' F250 - DD

1982 Toyota Pick-Up - Spray-On Yellow Rhino Lined - Chevrolet 305 H.O. - SM465 - NP208C - All-Pro Off Road 5" Springs - 35x15.50x15 Super Swampers
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post #10 of 79 Old 02-01-2012, 03:57 PM Thread Starter
cstone94
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Okay, so I did the gravity bleed. I started it up, started pumpin the clutch, nothing there still. Looked under the turd and its leaking. the hood was open so I spotted it pretty easily.


I can push the line down, and it'll stay, if I push in the clutch it pops out and starts leaking... Any ideas?
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post #11 of 79 Old 02-01-2012, 05:34 PM Thread Starter
cstone94
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Anyone? Trying to get this done tonight!
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post #12 of 79 Old 02-01-2012, 05:44 PM
jeepjerryp7m8
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Remove the fitting, take a picture of the O ring and fitting and post back. It looks like you didnt get the sitting seated all the way in.
Did you get the O ring into the groove? Can you grab the fitting and pull it out? Drive the pin half way out push the fitting all the way in and drive the pin back through.
Jerry
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post #13 of 79 Old 02-01-2012, 05:48 PM Thread Starter
cstone94
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I got new pins, and struggled to get the one that would fit in there. It's pretty hard to get out. I lost the O Ring, went to Advanced, and bought a HELP set. threw two on there. maybe I need to do something different?
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post #14 of 79 Old 02-01-2012, 05:50 PM Thread Starter
cstone94
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And the pin isn't gonna be easy to remove...

95' YJ - Warn Bumpers/Tire Carrier/Winch - 2.5L - 6" Skyjacker Suspension Lift - 4.10's - Locrite Locker - Dana 35/30 - 35" BFGoodrich KM2's

11' F250 - DD

1982 Toyota Pick-Up - Spray-On Yellow Rhino Lined - Chevrolet 305 H.O. - SM465 - NP208C - All-Pro Off Road 5" Springs - 35x15.50x15 Super Swampers
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post #15 of 79 Old 02-01-2012, 05:50 PM
jeepjerryp7m8
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You have 2 O rings on the fitting? Pull the fitting get a pic and post back up.
Jerry
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