Clutch Master Leak...again

I've converted to swinging pedals and been using a YJ clutch master cylinder. My slave cylinder came from a kit I bought from Novak, which is supposedly just a Toyota slave cylinder. Both master and slave have 3/4" bore.

I found out just now that the clutch master is leaking at the push rod, again! I just recently replaced the insides of this thing because of an initial leak.

What's causing this chronic leaking?

The Story:
During the first leak, I noticed though that the pedal had a slight 'scraping' feel to it. It could be that the pushrod is misaligned but it doesn't look like it. The fluid was gray when it leaked the first time. I figured the seals were chewed up so I bought a rebuild kit.

After rebuilding, it was working great. The 'scraping' feel disappeared and the pedal felt smooth when being pressed. A couple of weeks of use, I noticed that the fluid was gray...again. I bled and flushed the system twice. Then about two days of use, the fluid was gray...again. Got damn frustrated and just left the fluid how it was. After a couple of days of the jeep sitting, the pedal would feel low (air?), but then come back to normal after a couple of presses. I've been keeping an eye for leaks. Then this morning I went to check and there it was...the second leak.

should I just replace the clutch master or is there a deeper problem? help

 

I would say the grey is aluminum shavings from the pressure block (that your push rod rests on) which is being pushed to the side of the master cylinder. You need to have someone slowly push the peddle down while you observe a straight in throw on the piston.

 

I just checked and it looks like the throw isn't as straight as I thought.

Where the pushrod goes through the dustboot, the bottom area of the hole is chewed.


Here it is not pushed in.


Here it is pushed in.


man, I hope I can washer my way out of this one...otherwise, this could take a full day removing the pedal assy. and relocating the damn pin that holds the pushrod...

 

I hope thats an easy fix. Is the firewall maybe flexing on you? That off-set is the cause tho. You may have to make a 4"X4" heavy plate with 4 corner bolts to be able to washer yourself outa that mis-alignment.

 

I think I'm gonna go cruising now...

pedal pushed in


I have a 10"x10"x1/8" reinforcing plate welded on the other side.

I was able to do a couple of things to make it work. The pin on the pedal was just a bolt that I originally fastened to the pedal. I was trying to avoid removing the whole pedal assy., welding the existing hole, and drilling a new hole for the pin.. What I did was remove the bolt/pin, cut it, and welded the two halves back but with an offset. So the bolt/pin jogged up, raising the pushrod up a bit. Although that helped, it wasn't enough. So I added a washer on the lower bolt of the clutch master to tilt the master cylinder.

I'm going to flush it but not sure now whether I need to rebuild this clutch master again...???

Thanks!

 

Good show. Ride it man.