hydraulic clutch setup on mighty max

abstract · Post by **abstract** » Thu Jan 21, 2010 5:04 pm

thinking about going with a W58 tranny in the mighty max, but the only question now is what hydraulic master cylinder to use. Also how to set it up.

boise-nic · Post by **boise-nic** » Thu Jan 21, 2010 7:11 pm

Easiest way is to use the stock master with the stock slave. I used the stock pedal assembly and just brazed a new lever arm where the cable would normally hook to. At the end of the new lever arm, I drilled a hole to fit the little gold colored bracket from the stock DSM clutch. One end of the little gold bracket is the cotter pin that goes to the lever arm and the other is a threaded hole that the master cylinder threads into for adjustment.

The outlet in the firewall for cable is actually just tackwelded in place. You can take a drill and knock it out. After you do that, you'll have a perfectly sized opening for the master cylinder rod to slide though. I would rivet or weld a stiffener plate so that you don't flex the firewall too much.

I have pictures of how I did this, I'll post them up later. They do a better job of explaining it than me

2.3strokdtalon · Post by **2.3strokdtalon** » Thu Jan 21, 2010 7:53 pm

Please do post pics! I'll be doing this pretty soon and would love to see how someone else went about doing it.

boise-nic · Post by **boise-nic** » Fri Jan 22, 2010 1:50 am

Here is a picture from the inside. Like I said, the stock pedal and linkage is all reused. all I did was make a new lever arm that will give the correct throw. Having both the factory master and slave, all you need to do is shoot for is a full stroke on the master to ensure you have a full stroke on the slave. At first I was worried the angle was too agresive and it would wear on the seals but I compared my setup to the setup on an old supra at the junkyard they are about the same. Pushing the pedel about 1/2 way in makes the angle of the linkage perfectly in line with the cylinder. To get it right, I actually took and cut slots so I could slide the cylinder up or down to get the right angle. Worked out really good!

Here's a shot from the engine bay. I had to dent the brake booster a "little" because the hydralic line comes out too close to it. You could probably get away with moving it around and away from it...I was just lazy. You can see my little backing plate that keeps the firewall from flexing. I'm running the stock pressure plate for now so the clutch is nice and soft.

abstract · Post by **abstract** » Fri Jan 22, 2010 10:32 am

I thought about using the setup off a v6 truck. They are just hard to find.

citrus3000psi · Post by **citrus3000psi** » Tue Jan 26, 2010 4:59 pm

I used my donor eclipse "stuff" to make it work. Surprisingly it fit well. I made a post a while back about it with pics.

http://projectzerog.com/forum/viewtopic.php?t=1223

My master cylinder ended up hitting the intake so I switch to a small one.

Here is an updated pic of the engine bay.