cjboater

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
renegadeoc1@aol.com

michael.white@charter.net

On Jan 2, 1:42 pm, cjboater <cbcj...@hotmail.com> wrote:
> 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
> renegade...@aol.com

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

L.W.\(ßill\)Hughes III

Is the Fork's pivot ball in place? http://www.----------.com/clutch/
God Bless America, Bill O|||||||O
mailto:----------@----------.com
http://www.----------.com/jeep_bookmark.htm


"cjboater" <cbcj727@hotmail.com> wrote in message
news:aa0fa141-aea7-4ee4-a624-ae7fbfa15daa@d21g2000prf.googlegroups.com...
> 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
> renegadeoc1@aol.com



--
Posted via a free Usenet account from http://www.teranews.com

Jeff Strickland

If the old fork was broken, odds are that the ball fell out and you put the
clutch back together without the ball. Or, you found a large ball bearing
(about 1/2" in diameter) inside the bell housing and did not know where it
came from or where it goes.

Now you know.





"L.W.(ßill)------ III" <----------@----------.com> wrote in message
news:477c2400$0$26075$88260bb3@free.teranews.com.. .
> Is the Fork's pivot ball in place? http://www.----------.com/clutch/
> God Bless America, Bill O|||||||O
> mailto:----------@----------.com
> http://www.----------.com/jeep_bookmark.htm
>
>
> "cjboater" <cbcj727@hotmail.com> wrote in message
> news:aa0fa141-aea7-4ee4-a624-ae7fbfa15daa@d21g2000prf.googlegroups.com...
>> 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
>> renegadeoc1@aol.com
>
>
>
> --
> Posted via a free Usenet account from http://www.teranews.com
>

Earle Horton

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

"Jeff Strickland" <crwlr@verizon.net> wrote in message
news:spWej.2860$jX4.1317@trnddc07...
> If the old fork was broken, odds are that the ball fell out and you
put the
> clutch back together without the ball. Or, you found a large ball
bearing
> (about 1/2" in diameter) inside the bell housing and did not know
where it
> came from or where it goes.
>
> Now you know.
>
>
>
>
>
> "L.W.(ßill)------ III" <----------@----------.com> wrote in message
> news:477c2400$0$26075$88260bb3@free.teranews.com.. .
> > Is the Fork's pivot ball in place?
http://www.----------.com/clutch/
> > God Bless America, Bill O|||||||O
> > mailto:----------@----------.com
> > http://www.----------.com/jeep_bookmark.htm
> >
> >
> > "cjboater" <cbcj727@hotmail.com> wrote in message
> >
news:aa0fa141-aea7-4ee4-a624-ae7fbfa15daa@d21g2000prf.googlegroups.com...
> >> 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
> >> renegadeoc1@aol.com
> >
> >
> >
> > --
> > Posted via a free Usenet account from http://www.teranews.com
> >
>

cjboater

On Jan 2, 2:42 pm, cjboater <cbcj...@hotmail.com> wrote:
> I've got my brothers 85 cj7 with the 150" 4cyl, T4, dana300, with the
> hydraulicclutch. He brought it to me with noclutchaction
> whatsoever. I've worked on pretty much nothing but jeeps for about 15
> years, but this is my first four banger/hydraulicclutch. When I took
> it apart I found theclutchfork to be broken, pressure plate rusted
> and rickety, driven disc wasted, throwout bearing pretty bad, master
> cylinder leaking on firewall side.
>
> Replaced everything in theclutchsetup 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 noclutchengagement, i.e. cannot rolljeepwith pedal on floor.
>
> New parts are: master cyl, slave cyl,clutchfork, throwout bearing,
> pilot bearing, pressure plate, driven disc, and had the flywheel cut.
>
> Anyhelpwould be hugely appreciated!
> Chris Beck
> 404-304-6473
> renegade...@aol.com

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.

Stupendous Man

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?
--
Stupendous Man,
Defender of Freedom, Advocate of Liberty