Yes Dj,I have the same setup on my 90,I think it was mid to late 90's when they went to the external cylinder...this whole thing began with the slave cylinder blowing the seals,would have been a very fast and easy fix if i had that setup...SO,since there's no room in the garage,when it stops snowing I will be out pulling that mess back apart again i guess,Till then I have my 82 DJ5 to strighten the body on <light rollover>.

 

Is the DJ a mail jeep? I've always dreamt of converting a 2wd RHD mail jeep to a sweet little crawler
Anyway, sounds like we went through the same issues. Just a small bit of encouragement:
The whole thing comes apart and goes back together MUCH easier the second time. Just remembering stupid little things like the top bolts are easier to do and un-do when the whole tranny is unbolted and dropped down a few inches... Good luck man!

 

yeah,the DJ is a postal jeep,apparently it's based on a Cj5,but 2 wheel drive,2.5 pontiac,904 auto.I put 235/15's on it,from my ford truck,looks way better .thinkin i might eventually put in an xj drivetrain if it will work,and otherwise convert it to a cj5.
I stopped by the O'reilly's where i got my clutch kit,they said to just bring the whole thing is and they'll exchange the clutch kit for a new one.I had no reciept,but they looked it up on thier computer,and that's a good thing.I think part of the reason i dread the job,is even with the trans lowered the first time,I was unable to see those top 2 bolts and spent an afternoon jamming various sockets on the top bolts,before getting oen out to see they were E-12's.I replaced em with regular 3/8 bolts,so the whole job ought to go way better this time around!
At any rate,it'll be a few days now,I hacven't built my shop yet,which means i'm doing it all outdoors...and it just snowed again in Montana...

 

Use LOTS of extensions! I used like 2 feet of extensions and a universal on the end of it.
Yeah I had to return my whole clutch kit too. I'm glad I called first and asked about their policy otherwise I just would have brought in the slave. Good Luck! Sorry about the snow, but you live in Montana so you're probably used to it??

 

in the valley i live in,we don't actually get that much snow...I have the extensions,and a universal i use on those top bolts,I am glad I replaced those $*%# e-12's with reg 3/8 bolts in the top of the Bh now though,I think i spent half a day the first time beating sockets on to them,not knowing what they were until I got one out.Wouldn't have been so bad,but even with the trans dropped low I couldn't see them,think I need new glasses,lol.

 

clutch just went to the floor today... mushy and wouldn't come all the way back up unless i pulled up on the pedal. The master is full and when i pump the pedal there is no movement of the fluid in the uncapped master cylinder, so i'm assuming that is the problem (any advice?).

I gambled on it being the master cylinder and picked up one from Auto Zone. Put it in and moved the pedal with my hand only to have the plastic fitting on the shaft snap in two.

Am I moving in the right direction? If it's the internal is there merit in trying to find a bell housing with an external slave?

my jeep is a 1991 cherokee sport with a 5 speed manual tranny.

Would love any advice on this.

 

Remove the clutch pedal and see if it is bent where the rod from the master cylinder hooks up. Just fix one with the same problem. Hope this helps you.

 

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