So after it's been acting up for while, my clutch finally fails me ( of course as I'm trying to leave town). I knew something was up when I had to double clutch 1st and 2nd and then that finally failed me too. I got it home and looked all around the master/slave assembly. There seems to be only leakage coming from the slave on the bottom ( I checked under the dash too). I also found a broken o-ring/seal just hanging off the slave assembly. So in this case, would it be ok to just change out the slave cylinder? Of course, I would need to fill and bleed the system as well. If you've been through this, could you please mention any special tools I might need to get the job done? I've seen there was some pin in the back, do I need some set of punch tools? I've also seen someone use a pressurized hand pump for the bleeding.......what tools make this job easier for changing and bleeding?

Many thanks,
Andy
XJ classic 96 manual

 

Andy, it is okay to just replace the slave cylinder, bleed,etc . I run a 5 speed in my “93”, and cannot afford to do a hole sell replacement of all the components, be nice to do so if I could.

 

Since the slave is leaking and you found a busted seal, definitely replace it no need to do the master if it’s dry. For tools:
- Bleeder wrench (10mm)
- Punch (for the slave pivot pin tap it out gently)
- Pressure bleeder (or a vacuum bleeder) makes life WAY easier.

Bench-bleed the slave before installing. No crazy tools, just patience. Swap it, bleed it, and you’re golden.

 

Big thanks to both replies here. I got all the necessary tools together and will start tackling this in the AM - (It's to hot here in the afternoon!) . I know enough now from youtube to leave the plastic cover and straps on while installing. I understand that the straps hold everything straight. But man, leave the top/tip cover on - I guess I just don't understand the inner mechanics of it all yet. Many thanks again, let you know how it goes.

Best,
Andy.Raleigh

 

EDIT: Ok, I got the hose off the back of the cylinder, that was tough! Had to gently grab it with plyers. That was so hard to get off and now after two attempts, I can't get it back on without it leaking everywhere. This is a crap design.

EDIT: Well for the moment I am defeated. I tried 3x to attatch that hose to the slave cylinder. I'm guessing now I learned my lesson and why most people just replace the whole thing. On my last attempt I tried some plumber's tape and wow, it started holding....am I'm pumping the clutch and it's getting better and I'm getting excited.......POP! The hose just pops off. I suppose two things here 1) the tape kinda blocked where the pin went through to get a good grab on it 2) I later realized I had put the cap back on the master and was not bleeding, just building pressure. In my defense, this also tells me that my fix would not have lasted long and I'd be on the side of the road somewhere.

Just seems like a bad design overall. Took so much effort to get it off that it just wouldn't go back on 'factory'.
I will look at getting a complete and bled system but, if that design is much of the same I'm also going to look at one with the metal plated tubes, after market.

For anyone reading this, I will add that this job would have driven me stark mad if I did not have a box end ratchet for the 13mm bolts ( as many times as I had to do it),
I think it was a 3/8"...

But where do I use the 10mm again? I'm not seeing it (My method of bleed ending up by priming the slave by hand before install and finishing w/ the clutch pedal). The last thing I'm confused about is the O-ring hanging around the cylinder. I thought it broke off of the unit somehow but there is none on the new one anywhere.

Back to the drawing board.
Thanks for any input!

Andy

 

Get the pre-bled assy. Its worth the cost,