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Clutch problem, please help!

I've got my brothers 85 cj7 with the 150" 4cyl, T4, dana300, with the hydraulic clutch. He brought it to me with no clutch action whatsoever. I've worked on pretty much nothing but jeeps for about 15 years, but this is my first four banger/hydraulic clutch. When I took it apart I found the clutch fork to be broken, pressure plate rusted and rickety, driven disc wasted, throwout bearing pretty bad, master cylinder leaking on firewall side.

Replaced everything in the clutch setup with all new parts except the line. the hydraulic line is hard stainless line with about 3" rubber section in middle. It shows no signs of leakage or decay, but I cant see inside it.

After replacing all parts (everything but the line) and a massive bleeding effort I still have no clutch engagement, i.e. cannot roll jeep with pedal on floor.

New parts are: master cyl, slave cyl, clutch fork, throwout bearing, pilot bearing, pressure plate, driven disc, and had the flywheel cut.

Any help would be hugely appreciated! Chris Beck

404-304-6473 snipped-for-privacy@aol.com
Reply to
cjboater
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Chris,

You need to analyze where it's failing. Start at the top and work your way down:

- Is the plunger being pushed into the master cylinder (i.e. did you neglect to re-connect the pedal)?

- Is the return spring present on the pedal?

- Is there fluid in the master cylinder?

- Is there pressure at the master cylinder when you press the pedal (pull the line at the master)?

- Is there pressure at the slave cylinder (pull the line at the slave)?

- Is the slave cylinder mounted firmly to the clutch housing (I've seen the mount points break)?

- Is the rod from the slave cylinder pushed up against the clutch fork?

- Does the slave cylinder push the clutch fork?

- Do you have the spring connected that holds the clutch fork to the rod from the slave cylinder?

If the clutch fork is moving, then something's mucked up inside. Make sure the throwout bearing is in place properly, and there's spring tension.

Good luck!

Michael

Reply to
michael.white

Is the Fork's pivot ball in place?

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God Bless America, Bill O|||||||O mailto: snipped-for-privacy@billhughes.com
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Reply to
L.W.(ßill)Hughes III

Heh, there's a zillion parts in the picture Bill posted, with lots of different model years represented. I'm thinking the OP has part number

20, "Pivot, Clutch Slave Cylinder: 1980-86 CJ 4 & 6 (not shown) 52021 00" instead of the ball you are talking about. Chris, the test you are talking about is not definitive. Note that there are two slave cylinders listed, part number 23 in the drawing, one for AMC 4 cyl. and one for all others. You could conceivably have the wrong cylinder. Now do you feel resistance when you press the clutch pedal? Second, what happens when you depress the clutch pedal and crank the starter? Sometimes a new clutch will be "tight". I have seen people burn them on purpose to "loosen" them up. I don't recommend it, but sometimes you have to do, what you have to do.

Cheers,

Earle

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> God Bless America, Bill O|||||||O> > mailto: snipped-for-privacy@billhughes.com >
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bearing,

Reply to
Earle Horton

pedal on floor.

Dont have time this am to check out all these links, but will this afternoon. Alll of the points in michaels post are in correct order.

I guess I could have elaborated a bit more. I've Worked on pretty much nothing but cj's and early 70's gm a-bodies for about 15 years and know them very well, esp cj's, have a few myself. But, this is my first with the 4cyl and my hydraulic clutch with slave cyl (dealt with the concentric bearing before). So feel free to get technical, I'll get it.

As far as what ive got, 100% of all the parts appears to be installed

100% correctly. have gone back over and rechecked everything to assure its right. I'm considering temporarily adding a bit of length to the pushrod on the slave to see if I can artificially add some throw to the assembly. But dont really feel this is a good option and certianly not a long term one. Guess I'm gonna keep bleeding some more, though I'm pretty sure its air free. Im begining to get a bit suspect of the rubber section of line, but like I said it looks good, but very hard to see.

Once again, thanks for any help everyone, Chris Beck.

Note to self, and all others- stay away from the 4cyl cj's, this one is the stuff the worst nightmares are made of.

Reply to
cjboater

Try reverse bleeding. Using a new pump-type oil can, force fluid in from the slave bleeder to the reservoir. That will get all the air from a downhill system, some BMWs can only be done that way. If that doesn't fix it, something mechanical is wrong. Is the pivot ball new?

Reply to
Stupendous Man

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