Slave cylinder replacement, gap between slave and bellhousing - JeepForum.com
 
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post #1 of 7 Old 05-30-2020, 06:40 PM Thread Starter
max.
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Slave cylinder replacement, gap between slave and bellhousing

Good evening, I rebuilt my 4.0 on my 2002 TJ sport. When I went to try to start it today, I pressed in the clutch about an inch or two and it was very firm. I pressed a bit harder and the slave cylinder piston broke. I took the old slave out got a new one. While trying to install it there is a gap about 1/4" between the new slave and the bell housing. The old slave had a plastic spacer on it. However, it also is not as thick as the new one so it will not go on easily. Maybe at all. I don't think it's right to just crank down the bolts to draw the new slave in.img_20200530_192734_1590885268056.jpg

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post #2 of 7 Old 05-30-2020, 06:59 PM Thread Starter
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post #3 of 7 Old 05-30-2020, 08:46 PM
SHoppe715
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That’s normal. You tighten it up and the spring will compress a bit. There’s always just a small amount of pressure on the TOB from the slave cylinder spring.

The little plastic tabs are only there to make it easier to hit the dimple in the fork with the rod. They also keep the piston from popping out when it’s not installed. When I put mine in, I twisted them through the slots after getting the nuts started and you’ll probably hear or feel a little pop the first time you push the pedal down. Probably don’t re-use that spacer. The new one should have the correct length rod installed. There was an issue and a TSB due to the wrong length rod causing TOB noise.

Did you get a pre-bled assembly or did you swap them line and bench-bleed?

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post #4 of 7 Old 05-30-2020, 08:48 PM
SHoppe715
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But it won’t take much force. You can compress that spring with just your fingers. If its hard to push the pedal down after installing, you have other internal issues with clutch or TOB

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post #5 of 7 Old 05-30-2020, 09:14 PM Thread Starter
max.
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I'll try installing it. I should be able to press the clutch fork in with my fingers or the slave piston? I have a feeling the clutch fork isn't on their right or something related to it that would cause it to have no give. I am able to pull the fork towards me about an inch and then push it back. Does not rotate vertically or anything.
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post #6 of 7 Old 05-31-2020, 09:06 AM
SHoppe715
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Quote:
Originally Posted by max. View Post
I'll try installing it. I should be able to press the clutch fork in with my fingers or the slave piston? I have a feeling the clutch fork isn't on their right or something related to it that would cause it to have no give. I am able to pull the fork towards me about an inch and then push it back. Does not rotate vertically or anything.
The slave cylinder. You won’t be able to release the clutch (push on the fork) with only hand pressure. The hydraulic system gives you an increase in pushing force. You should be able to start the 2 nuts on the slave cylinder and it’ll suck down with minimal effort compressing the spring inside the cylinder. If the clutch resists when pushing the pedal then yes, there’s an issue up inside the bell housing.

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post #7 of 7 Old 06-01-2020, 08:37 PM Thread Starter
max.
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Well I got the slave working I believe with it bolted up. Now I'm getting a no start, so I'll start a new thread on that.
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