parts required and ordered from j&w autowreckers:
bell housing (external slave)
input spline for 231
t-case shifter and bracket
recommended but not required, new skidplate
you can call and ask for the drivetrain specialist and tell him what you are wanting to do.
luk pro-gold for dodge truck (complete kit), p/n:05-901
supplier: dial-a-clutch phone: 800-938-1195
cost: approx $200
mopar p/n 34665305
cost: dealer approx $175, can be found cheaper from omix-ada and crown retailers
before you install this setup, you have to remove/cut off the lower stud and drill a hole for a bolt approx 3/4" below the stud. you will have to drill out the plastic rod end to 1/2". the application that uses this setup uses a 3/8" clutch pedal pin. you will have to thin the width of the rod end some so you can get the cotter pin back into the clutch pedal pin, its about 5/16" thick when finished. you'll have to thin the rod end a total of an inch in diameter from the center of the rod end's hole
i found out after i replaced the whole assembly (my first one), you can replace just the failed part (slave, master or hose) by tapping out the roll pin at the swivel joints. a fine place for piece parts or whole assembly for this setup is www.restore4x4.com
. i am not sure, but if you are very handy with making tubes, but you may be able make a line from the original hydraulic cylinder to a metal (bodied) slave. i do not know how feaseable this is. i went with the easier option and i do not know if the metal slave will work for this application.
cost varies. it is VERY important you specify a long front retainer, small pilot transmission. this is the best tranny for this conversion. it allows you to use the factory pilot bearing. later model cherokees use a different t-case shifter bracket than do the wranglers. make sure you get the tranny housing that matches your shifter style.
since you are gonna be in the t-case to replace the input spline, why not do a sye conversion too. best personally recommended source is tom wood's custom driveshafts. www.4xshaft.com
great guy and even better service.
in the end, its gonna run close to $2k. but.....it eliminates alot of worries and headaches. the external slave cylinder makes its a piece of cake to replace if it starts leaking, as opposed to the ba10/5's internal slave. here are a few pics of the clutch setup. at the very worst, you lengthen the t-case/tranny assembly by about an inch.