Hi,

I've got a 96 4.0 with an ax-15. 200K+ miles. Before I bought this Jeep a year ago the PO had replaced the master cylinder. Not sure if they also replaced the rest of the hydraulic clutch system. It has stayed bled and no real issues in the year I've had it. My question is, is there any way to adjust, or do they make different length pushrods going from the pedal assembly to the master? I've got over an inch of play at the pedal before the pushrod actually contacts the cylinder piston. I know you want a little free-play, but this is excessive. While the clutch engages just fine (don't know it's history), it takes just about every inch of travel to change gears, especially cold. Not a HUGE deal, but it is annoying. I feel like if pushrod engaged earlier, I wouldn't be stomping to the floor to get into second.

I do not suspect any air in the system. I've done the yoga routine and gotten my head up under the dash, to watch all the slop in the linkage. There is some at the "pin", and then when that is over, there is still more slop waiting for the pushrod to make contact with the cylinder.

My next question is, if the system is truly non-adjustable and there are no longer pushrods, is it a terrible idea to take the rod out, weld a lump on the end, grind it nice, and try it?

Thanks!

the pedals are known for the tab bending and breaking neat the top. Do some more yoga.

Trying to picture what you mean. Do you mean the top of the pedal that sets the "rest position". I suppose if I messed with that, re-bending or adding spacers I could take up the slop, but then my clutch pedal would be permanently lower, and I feel it is sitting in the right spot now. It is even with the brake pedal. Plus, I wouldn't actually give me any more travel, which I was hoping to achieve.

Poor description on my part. The pedal begins to separate from the pivoting part of the pedal.