I've got a 96 D21 4x4 with 2.4 and a 5 speed. The clutch (I believe original with 99k) has been acting weird lately. A few times when I first start the truck in the morning, with the clutch fully depressed when I turn the key the truck jumps forward like the clutch is engaged. 2nd try and it's fine. Also a couple times on the 2nd gear shift it will spin free for a few seconds after I let the clutch out and then grab like I popped it. It seems to be getting increasingly harder to get it into gear as well.

The clutch doesn't seem to slip even when lugging it up a hill (I don't regularly drive like this but have tried it to test the clutch)


Is this just weird signs of a clutch going south or could it be something else?

thanks BC

slave cylinder is my guess.

I'd bleed the clutch line at the slave cylinder and see if that helps. Also, if the slave is going out, its best to replace both the master and slave at the same time. If you do one or the other, the part you didnt replace will usually go out shortly after.

Cool, thanks guys. Would it be a fairly straight forward job if I were to try it myself?

Replacing the master and slave isnt hard at all.. you'll just need to pick up a good 10mm line wrench (I'd get a whole 3 wrench 6-size set for future tasks) for disconnecting the hydraulic lines. Other than that, it just requires normal wrenches and a socket set. When you get it all together, you will need an extra hand (or foot) to bleed the system to get all the air out.

When removing the old stuff, just make sure not to get brake fluid on the paint. It will remove paint just like paint stripper if left to sit on paint.

Bleeding the system is easy, although can be messy. I picked up a $25 vacuum bleeder kit to make the task as clean as possible. Like I said before though, you will need a helper to press the clutch pedal down while you open the bleed valve.

Post Jack: Good looking 96HB you got there. :Back to post.

Good deal, thanks Datz- looks like the parts are pretty cheap so gettin a few decent tools to do the job right should be do-able.

Thanks Curry. It's not easy keeping it looking good with all the salt they use on the roads in western NY but after losing my 87 HB to rust (that still ran great with 240K on the odo), I've sworn to keep this one as clean as possible

I did my hardbody clutch master in under 30 minutes one afternoon just goofing off the whole time. Definately ranks easy.

Finally got around to getting it done this weekend. Couldn't have been easier. I didn't even need a line wrench because mine had a banjo fitting on the cylinder. I forgot how easy the truck was to drive when the clutch was functioning properly. Thanks again guys.