Dodge Power Wagon W200 Hydraulic Clutch System

My clutch on my W200 Power Wagon was mechanical and no hydraulic system was offered. The guy at the workshop said it is not possible to do it... Which triggered me so bad, thats why I decided to design my own. First of all, to be on the safe side I decided to get the longest stroke slave and master cylinders possible which are mainly Pull Type cylinders. Many reviewers had negative feedbacks about the pull type products so I wanted to go for push type which required the measure the total amount of travel necessary for disengage.

I found out that Slave Cylinder from Dorman is more than enough for the job. The part code is CS 360003 (33$). It is a 1" diameter, aluminum body slave cylinder for RAM trucks which approves that it is strong enough for task.




For Master Cylinder I found 7/8" diameter CNC Brakes 71178 (Steel  Body) or CNC71278 (Aluminum Body with steel sleve).




I fitted the master cylinder with a reservoir I found from Ali Express.

Aluminum Racing Drift Hydraulic Handbrake Hand Brake Oil Tank Fluid Reservoir E-brake

Unfortunately the size of the threads did not fit to the master cylinder so I had to machine an adapter for master cylinder and reservoir but the result was perfect.

Now it was time to adapt pedal fittings. 

I already ordered master cylinder fitting with the cylinder but of course, the main shaft was short for my application. I have fabricated the adapter between pedal and master cylinder.

Then a modification to the pedal was necessary to accept CNC Brake fitting (Blue part):

I welded the bracket to the pedal and drilled several holes for adjustment. 

Then it was time to drill the firewall, I found the location using extension pin and drilled with a punch. 

Now it is slave cylinder brackets turn. Below is the design of the bracket. 

Bracket is bolted to the bellhousing. Now comes another problem, even though I placed the slave as close as possible to the bellhousing the fork and slave are not inline. So I had to produce an fork extension like this:

Also I designed my push rod mechanism using link ball bearing to prevent any extra friction. 

I also had to get a specifically manufactured hydraulic hose which connects between master cylinder and slave cylinder. 

After bleeding my clutched worked perfectly. No gear grinding, no hard clutch pressure, it worked like a charm. Then I realized that my firewall flexed terribly during clutch operation. The sheet metal thickness was not enough to withstand the pressure of the master slave so I strengthened the firewall with two brackets, from inside and outside to prevent flexing. 

This modification ensured that everything will be strong enough for heavy duty functioning.