1994 AX5 to AX15 Conversion - Page 4

**Opihi59** · 10-31-2009, 03:05 PM

Not too terribly long ago, like this past summer, I asked to look at some external slaves at Checker's--they had the ones with the bleeder......you may be able to swap in another ext slave. The one in my photos with the bleeder I rescued from a junk yard, you could likely find one there, or even find a bleeder screw from a brake system that could fit with a few minor modifications.
If you do end up getting a new one, try drilling out the old one, or even send it to me so I can play with it and report my findings/photos--I'll be back in Honolulu in Jan. PM me for an address if you want.

Hope you get this running soon.

**UltimatE** · 10-31-2009, 03:05 PM

Could it also be the pilot bushing I used? I ordered it from Advance Adapters, it fit snugly into the flywheel and I test fit it to the input shaft. It said to soak it in motor oil over night before installing, which I did.

**Opihi59** · 10-31-2009, 03:11 PM

Not likely to be a problem. I would imagine your transmisison/bellhousing is bolted back up completely? You'd know if the input snout didn't fit into the pilot--your bellhousing would be standing about 1/2 inch away from bolting tight to the block...

**Mean Max** · 10-31-2009, 03:11 PM

Quote:

Originally Posted by UltimatE

Could it also be the pilot bushing I used? I ordered it from Advance Adapters, it fit snugly into the flywheel and I test fit it to the input shaft. It said to soak it in motor oil over night before installing, which I did.

No, that wouldn't affect clutch release. It sounds like you did the pilot bushing properly though.

Max

**UltimatE** · 10-31-2009, 03:15 PM

Quote:

Originally Posted by Mean Max

No, that wouldn't affect clutch release. It sounds like you did the pilot bushing properly though.

Max

It wouldn't affect clutch release, correct; However it would present the same problems as an improper clutch release by still supplying torque to the transmission. Maybe the clutch is releasing?

**Mean Max** · 10-31-2009, 03:20 PM

Quote:

Originally Posted by UltimatE

It wouldn't affect clutch release, correct; However it would present the same problems as an improper clutch release by still supplying torque to the transmission. Maybe the clutch is releasing?

You know that's a good point. If the input shaft is "dragging" on the pilot bushing, it might just mimick a release issue.

Hmm.......

Max

**UltimatE** · 10-31-2009, 04:32 PM

I'm pretty sure its the pilot bushing at fault. I put the jeep in gear, held down the brake pedal and started it with the clutch pedal pressed in. It wanted to move forward a little bit. I slowly released the clutch and it grabbed significantly at one point, near the top of fully releasing the clutch.

Not the answer I wanted ... Means I'm going to need to redo everything, since the pilot bushing is the absolute first thing to put in during assembly.

Does anyone know if the Dakota pilot bearing will fit in the Jeep flywheel?

**Mean Max** · 10-31-2009, 04:40 PM

Quote:

Originally Posted by UltimatE

I'm pretty sure its the pilot bushing at fault. I put the jeep in gear, held down the brake pedal and started it with the clutch pedal pressed in. It wanted to move forward a little bit. I slowly released the clutch and it grabbed significantly at one point, near the top of fully releasing the clutch.

Not the answer I wanted ... Means I'm going to need to redo everything, since the pilot bushing is the absolute first thing to put in during assembly.

Does anyone know if the Dakota pilot bearing will fit in the Jeep flywheel?

I don't know about the Dakota pilot bearing, but the AX-15 should have a .590 or a .750 input shaft.

There has to be a regular needle type pilot bearing that has the OD & ID you need.

Do you recall your bushing's OD?

Max

**UltimatE** · 10-31-2009, 04:44 PM

According to Advance Adapters:

Inner Diameter:
.750
Length:
.953
Outer Diameter:
.947

Which is confusing because the title of that page also denotes: .750 ID X 1.090 OD

**Mean Max** · 10-31-2009, 04:51 PM

Quote:

Originally Posted by UltimatE

According to Advance Adapters:

Inner Diameter:
.750
Length:
.953
Outer Diameter:
.947

Which is confusing because the title of that page also denotes: .750 ID X 1.090 OD

When you remove it, you'll just have to measure it to be sure.

I did find a little something on Novak's site that may be interesting.

The Novak Guide to Clutches, Linkages & Bellhousings for Jeeps

"The job of the pilot bushing is to support the end of the transmission input (main drive) gear in the crankshaft and it only acts as a bushing when the clutch is depressed. This pilot bushing should be a light drive fit into the crank bore. Care should be taken when installing any pilot bushing as they are soft and easily damaged by crude installation techniques. A damaged pilot bushing can bind on the input gear giving symptoms of clutch drag."

Engine Crank to Transmission Input Shaft Pilot Bushings

Max

moonshinefuel · 11-01-2009, 10:07 AM

Quote:

Originally Posted by UltimatE

I'm pretty sure its the pilot bushing at fault. I put the jeep in gear, held down the brake pedal and started it with the clutch pedal pressed in. It wanted to move forward a little bit. I slowly released the clutch and it grabbed significantly at one point, near the top of fully releasing the clutch.

Not the answer I wanted ... Means I'm going to need to redo everything, since the pilot bushing is the absolute first thing to put in during assembly.

Does anyone know if the Dakota pilot bearing will fit in the Jeep flywheel?

The 96-98 Dakota pilot bushing will not fit the i.d. of the ax5 flywheel. The Dakota bushing on right has a larger o.d. and will not fit the inside of the ax5 flywheel. (not on my 1995) AX5 bushing is on left. The 96-98 Dakota flywheel will fit though, and the crank sensor notches are the same for my 1995 2.5 engine.

moonshinefuel · 11-01-2009, 10:39 AM

I spent months dissecting this information and confronting these issues with the help of others. I had a similar situation where the input shaft was jamming into the pilot and I honed it out some. I tested the fit with the flywheel off the engine with pilot in, and test to shaft. I will not be using the the NV4500 pilot bushing as I believe the needle bearing pilot bushing with the dakota clutch/flywheel is a better setup, however more money. So you have to weigh in these factors. If it is fitting too tight, you may want to consider honing. Otherwise plan on shelling out for a new clutch and flywheel. The dakota clutch is more expensive than the ax5 clutch as well. Here is the page where I covered some of what you are talking about. Even if the Dakota pilot did fit the AX5 flywheel, the AX5 flywheel has a counter sink in the center, it is machined at an angle into the center of the hub, bringing the pilot bushing further away from the shaft and may very well run into problems there with the input shaft not dropping into the pilot deep enough, or at all possibly. http://www.jeepforum.com/forum/f12/nv-3550-4-angry-squirrels-752742/index9.html

**UltimatE** · 11-01-2009, 11:54 AM

Got the transmission out and sure enough the part of the input shaft that rides in the pilot bushing is burnt brown.

Edit: Just got the flywheel off, and slipped it onto the input shaft. It went on pretty easily and I can rotate the flywheel on the input shaft and hold the output shaft by hand and it won't turn. Not sure why the contact surfaces are burnt though.

**UltimatE** · 11-01-2009, 01:02 PM

I'm stumped at this point...

**Mean Max** · 11-01-2009, 01:20 PM

Quote:

Originally Posted by UltimatE

I'm stumped at this point...

Go to this link (I actually posted it earlier) and read the entire section on pilot bushings. I think there is an alignment problem somewhere that is causing the shaft to enter the hole in the bushing either at an angle or off center.

The Novak Guide to Clutches, Linkages & Bellhousings for Jeeps

I really think that you should make every attempt to source a needle bearing style pilot bearing, as opposed to a bushing.

I really wish I could be there to put my hands on this & try to get a feel for what you're dealing with. Working over the internet is tough.

Max