Been thinking of doing this for a while but my jeep decided it was time.. The bellcrank to pushrod arm snapped clean off.
After limping it the remaining 10 miles home I pondered for a while my course of attack. Repair and reinforce my current parts, purchase a replacement bellcrank or upgrade to hydraulic clutch. Upgrade..... Everytime anything breaks that's what I have to do. Then I started thinking about how nice it would be to lighten my clutch pedal force by at least half.. No more leg cramping workouts in afternoon traffic. No more linkage to wear and fall out of adjustment.
First thing is parts. Slave is a 81-83 cj7 with gm 151. Bolted right up to my t15. It used the bottom and center hole vs. the top and center used by the stock linkage.
The master cylinder is one I had lots of previous experience with. A 88 yj. Also I got 4 feet of 3/16" brake line and a flex hose I had sitting around from some unknown previous project. Also a lot of brake fluid, a 1 1/2" hole saw and 4 5/16-18 bolts and nuts. Total parts cost- just under $100.
First step remove old parts and linkage. Mount slave and pushrod to tranny using 2 5/16-18 bolts 1" long using bottom and center hole. Next- unscrew fusebox and push to the side. Remove clip holding clutch pedal on. Slide to side taking care through this whole process not to dislodge needle rollers. I put a socket that fit snuggly in the center to prevent this.
Grind the 2 rivets holding the bracket to the pedal then knock them out.
Next measure then drill using the 1 1/2" hole saw the hole in the firewall for the master to mount. Using the master as a template mark and drill 2 5/16" holes to bolt it to the firewall. Once done bolt it to the firewall.
Next slide clutch pedal on. Align it to the correct height, then align the master pushrod and mark. Remove and drill the hole. It was a 7/16" for me. I then welded a nut on the other side. Install pedal then pushed to pedal. Check for proper travel with no binding and install return spring. Reinstall fuse box. Run brake lines and bleed. Test drive and enjoy the much lighter smoother clutch.
All in all took about 2 1/2 hours and minimal skill.. Very pleased. My leg is so much happier. Next up this weekend- install my yj booster and have power brakes...