Truth is Stranger than Fiction
 

This is follow-up to my previous question "Can I re-build it?" referin
to the clutch master cylinder in my 91 Cherokee Laredo (175K).
ordered a new master cylinder on line. Received it no problem. Sunda
project, my DH and I got under the shade trees to change it out.
Everything went along real well. As we're tightening up the nuts on th
new master cylinder, DH said"this is the easiest thing we've done o
this vehicle" (he shouldn't've said that)." He says “Get in there an
slip that push rod on the foot pedal and stick the keeper clip in it
(yep, going good! and it's not even noon yet!)
OK I admit I'm a better go-pher than a do-er, but shouldn't be tha
darn hard to slip this thing on there! WILL NOT GO!! (like I said, h
shouldn't've said that!)
What the heck?! Won't line up. Get to looking at the foot lever
looks bent! How in the world? Thick as that metal is? Well, well
well, looks like the union auto worker must've taken a coffee brea
between welding the back side and welding the front side of the lever'
pivoting mounting bracket at the firewall! So, a weak weld and a stron
leg trying to get clutch clearance to shift gears --- bent clutch lever
OK, take the whole mounting bracket out, realign the clutch lever, wel
it. Re-install the bracket, master cylinder push rod slips right on th
pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
Time to test it …. Won’t shift …. Not enough pedal …. Feels like I’
trying to push it thru the floor to get clearance! What the heck?!
(did I say, he shouldn’t have said that?!)
Frustrated now! I get back under the dash, push the clutch with m
hand and see that the lever is completely on the floor and indentin
the carpet. Fruussttrated … I’ll pull the dang carpet out …. I onl
need a little more clearance! Take the interior strips out that hol
the carpet in place on the driver’s side, pull the carpet out of th
way, push the clutch pedal …. The lever is on the bare metal floor !!!
aarggg --- the dang push rod in the new master cylinder is TOOOO
SHORT!!!! …………………………
DH builds an extension for the push rod, put it back on the clutc
lever ….. works great!!! And it’s only 6pm … It’s been a couple o
months now, shifts like brand new Jeep!!
The truth as I think it was …. There was likely nothing wrong with th
master cylinder to begin with …. Over time, the non-welded clutch leve
gradually moved enough that the master cylinder push rod became “to
short” for the longer distance caused by the bent lever


--
CherokeeGirl

Re: Truth is Stranger than Fiction
 

Great story!
Thanks for the grin :)

Kate

"CherokeeGirl" <CherokeeGirl.2g8wz2@news.autobanter.com> wrote in message
news:CherokeeGirl.2g8wz2@news.autobanter.com...
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says "Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it .. Won't shift .. Not enough pedal .. Feels like I'm
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn't have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated . I'll pull the dang carpet out .. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver's side, pull the carpet out of the
> way, push the clutch pedal .. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! ..........
> DH builds an extension for the push rod, put it back on the clutch
> lever ... works great!!! And it's only 6pm . It's been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was .. There was likely nothing wrong with the
> master cylinder to begin with .. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became "too
> short" for the longer distance caused by the bent lever!
>
>
>
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

Great story!
Thanks for the grin :)

Kate

"CherokeeGirl" <CherokeeGirl.2g8wz2@news.autobanter.com> wrote in message
news:CherokeeGirl.2g8wz2@news.autobanter.com...
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says "Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it .. Won't shift .. Not enough pedal .. Feels like I'm
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn't have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated . I'll pull the dang carpet out .. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver's side, pull the carpet out of the
> way, push the clutch pedal .. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! ..........
> DH builds an extension for the push rod, put it back on the clutch
> lever ... works great!!! And it's only 6pm . It's been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was .. There was likely nothing wrong with the
> master cylinder to begin with .. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became "too
> short" for the longer distance caused by the bent lever!
>
>
>
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

Great story!
Thanks for the grin :)

Kate

"CherokeeGirl" <CherokeeGirl.2g8wz2@news.autobanter.com> wrote in message
news:CherokeeGirl.2g8wz2@news.autobanter.com...
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says "Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it .. Won't shift .. Not enough pedal .. Feels like I'm
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn't have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated . I'll pull the dang carpet out .. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver's side, pull the carpet out of the
> way, push the clutch pedal .. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! ..........
> DH builds an extension for the push rod, put it back on the clutch
> lever ... works great!!! And it's only 6pm . It's been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was .. There was likely nothing wrong with the
> master cylinder to begin with .. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became "too
> short" for the longer distance caused by the bent lever!
>
>
>
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

Wow, what a pain of a fix! Nothing like having to make a 'custom'
clutch.

I would have almost been thinking about getting one from the wreckers if
I found mine like that.... But then again I do have a little wire feed
'mig' welder.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

CherokeeGirl wrote:
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says “Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it …. Won’t shift …. Not enough pedal …. Feels like I’m
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn’t have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated … I’ll pull the dang carpet out …. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver’s side, pull the carpet out of the
> way, push the clutch pedal …. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! …………………………
> DH builds an extension for the push rod, put it back on the clutch
> lever ….. works great!!! And it’s only 6pm … It’s been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was …. There was likely nothing wrong with the
> master cylinder to begin with …. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became “too
> short” for the longer distance caused by the bent lever!
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

Wow, what a pain of a fix! Nothing like having to make a 'custom'
clutch.

I would have almost been thinking about getting one from the wreckers if
I found mine like that.... But then again I do have a little wire feed
'mig' welder.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

CherokeeGirl wrote:
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says “Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it …. Won’t shift …. Not enough pedal …. Feels like I’m
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn’t have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated … I’ll pull the dang carpet out …. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver’s side, pull the carpet out of the
> way, push the clutch pedal …. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! …………………………
> DH builds an extension for the push rod, put it back on the clutch
> lever ….. works great!!! And it’s only 6pm … It’s been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was …. There was likely nothing wrong with the
> master cylinder to begin with …. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became “too
> short” for the longer distance caused by the bent lever!
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

Wow, what a pain of a fix! Nothing like having to make a 'custom'
clutch.

I would have almost been thinking about getting one from the wreckers if
I found mine like that.... But then again I do have a little wire feed
'mig' welder.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

CherokeeGirl wrote:
>
> This is follow-up to my previous question "Can I re-build it?" refering
> to the clutch master cylinder in my 91 Cherokee Laredo (175K). I
> ordered a new master cylinder on line. Received it no problem. Sunday
> project, my DH and I got under the shade trees to change it out.
> Everything went along real well. As we're tightening up the nuts on the
> new master cylinder, DH said"this is the easiest thing we've done on
> this vehicle" (he shouldn't've said that)." He says “Get in there and
> slip that push rod on the foot pedal and stick the keeper clip in it"
> (yep, going good! and it's not even noon yet!)
> OK I admit I'm a better go-pher than a do-er, but shouldn't be that
> darn hard to slip this thing on there! WILL NOT GO!! (like I said, he
> shouldn't've said that!)
> What the heck?! Won't line up. Get to looking at the foot lever,
> looks bent! How in the world? Thick as that metal is? Well, well,
> well, looks like the union auto worker must've taken a coffee break
> between welding the back side and welding the front side of the lever's
> pivoting mounting bracket at the firewall! So, a weak weld and a strong
> leg trying to get clutch clearance to shift gears --- bent clutch lever.
> OK, take the whole mounting bracket out, realign the clutch lever, weld
> it. Re-install the bracket, master cylinder push rod slips right on the
> pin!!! Yeah, home free !!!!! Fill master cylinder , etc, etc, etc.
> Time to test it …. Won’t shift …. Not enough pedal …. Feels like I’m
> trying to push it thru the floor to get clearance! What the heck?!
> (did I say, he shouldn’t have said that?!)
> Frustrated now! I get back under the dash, push the clutch with my
> hand and see that the lever is completely on the floor and indenting
> the carpet. Fruussttrated … I’ll pull the dang carpet out …. I only
> need a little more clearance! Take the interior strips out that hold
> the carpet in place on the driver’s side, pull the carpet out of the
> way, push the clutch pedal …. The lever is on the bare metal floor !!!!
> aarggg --- the dang push rod in the new master cylinder is TOOOOO
> SHORT!!!! …………………………
> DH builds an extension for the push rod, put it back on the clutch
> lever ….. works great!!! And it’s only 6pm … It’s been a couple of
> months now, shifts like brand new Jeep!!
> The truth as I think it was …. There was likely nothing wrong with the
> master cylinder to begin with …. Over time, the non-welded clutch lever
> gradually moved enough that the master cylinder push rod became “too
> short” for the longer distance caused by the bent lever!
>
> --
> CherokeeGirl

Re: Truth is Stranger than Fiction
 

DH?

"I
>> ordered a new master cylinder on line. Received it no problem. Sunday
>> project, my DH and I got under the shade trees to change it out.
>>

Re: Truth is Stranger than Fiction
 

DH?

"I
>> ordered a new master cylinder on line. Received it no problem. Sunday
>> project, my DH and I got under the shade trees to change it out.
>>

Re: Truth is Stranger than Fiction
 

DH?

"I
>> ordered a new master cylinder on line. Received it no problem. Sunday
>> project, my DH and I got under the shade trees to change it out.
>>