Anyone using a 96 up style GM slave cylinder? Just curious what your using for a clutch master cyl?
I'm trying to come up with a suitable clutch master for my FJ60/6.2 Chevy/NV4500
.
I don't think the Toyota clutch master will move enough fluid, and the 96 up Chevy unit is a plastic POS that twists and turns into an opening in the firewall. 96 up Chevy unit designed for it looks like it is a small bore (.72 dia) long stroke.
.
I couldn't use an AA or Marks bell housing because the nose of my 6.2 diesels' starter wouldn't fit, and I got a 96 up GM internal cyl bell housing.

If anyone has been down this road, any advice appreciated, Thanks!

don't know about the chevy but my friends fj40 70' with boosted dual resevior had enough to push the dodge internal slave on the 318 he put in.

I despise internal's, seems as if they give too much trouble and it is a PITA to replace them. go with the Toy esternal, I've done a couple of NV's and it works fine
Butch

yeah, what butch said. even though i'm not sure what "esternal" means! :flipoff2:

you could also use a pull type slave, like Willwood makes. I have been running it on my set up for a long time, though am now onto my 4th slave in about 7 years. I think I finally figured out the problem though, and all should be good with it. Pull is enough for a chevy clutch.

I looked into this and ran into many of the same problems and I agree w/ everyone else...

Also, what year and type NV4500 do you have, a GM style '96 and later version? Even so, are you sure about the 6.2 starter?

If you don't already have a Dodge SD NV4500:
Swap the front bearing retainer for an early Chevy NV4500 retainer, they are interchangable. Then use a standard external clutch fork that will come with your AA kit to get the NV4500 behind the Chevy 350. Then use your toy slave and toy master, works great. Use a heavy duty chevy 350 clutch otherwise you'll find that even your Toy external master/slave setup will not move enough juice but a HD 350 clutch will be beyond fine... I used the OEM clutch (a 454 one, same as what you'd get with a stock 6.2 clutch I imagine) and had to use a high vol. Wilwood brake master as my clutch master and it is a stiff pedal.

If you find out for sure that you can't use the AA kit, then swap the input shaft when you are swaping bearing retainers to a Dodge standard duty input gear (AA part#52019 - $102). Then you need to use a Dodge SD bearing retainer, then the front of your NV4500 (even though it's a Chevy version) is basically a dodge SD version up front. Then follow directions for using AA's plate style adapter that mates a SM465 bellhousing (stock behind 6.2's) to the NV4500 via the plate...

AA's directions will mention that you have the sleeve of the bearing retainer machined down to chevy spec (Machine shop charged me $30). Plate style adapter w/ kit that includes pilot, etc (about $300ish last I remember even though the part number I think it is [AA part# 577577] lists at $377 which is a lot of money considering what it is, but it still should work... I would (and did) use the early 72-74 SM465 bellhousing (preferred over the later aluminum ones, plus they are open bottom), any of these will have a 5.125" bearing retainer diameter which is how AA refers to it (they don't call it a "SM465 bellhousing" even though that is what it is). In all done and told you'll be in it about $500-600 and have a bomber setup, 10x stronger than using an AA kit anyways. I did the same thing, but in my case basically because I had to. I was into the whole swap less than $400 done and told but I paid $250 for the AA adapter plate and $30 for the bellhousing.

yeah, what butch said. even though i'm not sure what "esternal" means! :flipoff2:

Yeah, right, you know it meant I f'd up typing eXternal.........

Butch :flipoff2: :flipoff2:

Here is a photo of the plate adapter and Dodge SD trans I used with the early SM465 bellhousing, FWIW

http://www.collegeinternetsolutions.com/cisautoweb/fj55/birfie_9_1203/drivetrain.jpg

I guess I'm a day late and a dollar short to change my plan of action.
I already bought my 96 up GM version NV4500, bell housing and internal slave cylinder.
AA told me that their bell housing couldn't be used with the diesel starter.
I did try an aluminum bell housing off a Chevy gas truck and the 6.2 starter hit at the bottom.. I never thought trying the early open bottom SM465 bellhousing or getting the bearing retainer machined down.
Lack of research on my part.

I got too much invested in my setup. Thanks for the great advice. I'll use it next time around.

Just hope it doesn't turn out to be problems. Maybe it will be ok from a strength standpoint since it will see daily driver and light trail use.

Dieselcruiserhead, What's that 4BT Cummins in or going in?
I'll check out your website. Thanks!

Website is way old unfortunately. 4BT is in my 55, it needed a SOA to get in because it's deep but was way easier to put in than even a Chevy 350 just like your 6.2 probably will be...

You can make the Chevy NV4500 work. If you want to take the route I mentioned that is what I did and it's fine. Problem with using the plate adapter with your Chevy version as is, is the input shaft is 1" shorter than the Dodge SD shaft (same diameter and spline count, slightly wider pilot tip though) so that is how the plate adapter works... The big secret is getting the AA NV4500 catalog... It will explain everything. I also can't guarantee the early bellhousing will work with your 6.2 but I imagine it probably will, especiallys since some of those 6.2's came with 465's behind them. No big deal, jsut change the input shafts and retainer and you are good to go. Get the Dodge bearing retainer machined to chevy spec and it is a pretty easy install.. AA will sell you all of the parts directly setup correctly so that is probably the easiest route. You can probably change the input shaft yourself pretty easily though I have never done it so I can't speak to the difficulties but most make it sound pretty easy... Good luck - who knew about the difficulties. What is your plan for the back of the NV4500, do they make an adapter for the chevy output to a LC tcase and/or is this your route?

PS - and don't worry I actually did the same exact thing, ordered a Chevy 32 spline rear output NV4500 then started worrying about it and literally had them tear it down halfway through and rebuilt it into a Dodge SD version... So my cheap $1200 NV4500 turned into a $1500 one real quick...

Honestly you will be fine though...

Also, you can use a Wilwood high volume brake master, and that should do the ticket except that I can't stand those internal slaves either but I guess you gotta do what you gotta do...

This is the one I used, from Summit $50
http://www.wilwood.com/Products/MasterCylinders/003-HVAMC/index.asp

I know some people have used them quite a bit on this board with varying results. You have to drill your firewall but works fine with the stock pedal. Also make sure your pushrod into the slave retracts 100% otherwise it will keep adding and adding fluid without letting fluid out and you will pop your new slave....

In a few days even possibly I might sell my 7/8" one for a song assuming I can make the stock one work again. I was using the Wilwood's massive amount of throw to compensate for some other problems I was having with my clutch fork and throwout bearing which have now (finally) been corrected...

Best, Andre