1994 AX5 to AX15 Conversion - Page 7

**UltimatE** · 11-05-2009, 02:33 PM

I know this may sound like a silly question, but none of the symptoms would be caused by not filling the transmission with oil, could it? I didn't think to mention it because I drove the Jeep with the AX-5 and no oil in the transmission without an issue (Moving it around my driveway) after it blew a hole in my driveway. I didn't want to fill the transmission or transfer case up until I knew it was working correctly.

moonshinefuel · 11-05-2009, 02:37 PM

You make me extremely nervous UltimatE.

**UltimatE** · 11-05-2009, 02:46 PM

Quote:

Originally Posted by moonshinefuel

You make me extremely nervous UltimatE.

Haha why is that?

**UltimatE** · 11-05-2009, 03:03 PM

Now that I think about it, increased internal friction from a lack of oil would actually work in my favor in preventing the input shaft from spinning.

**UltimatE** · 11-05-2009, 04:57 PM

Okay, so I dropped the transmission. (In a whopping 1.5 hours including eating and other stuff)

As we suspected, the clutch disc splines do indeed look to be very close to the fingers of the pressure plate. I am going back out now to get some measurements.

moonshinefuel · 11-05-2009, 05:07 PM

If you can post pictures, it definitely helps.

**UltimatE** · 11-05-2009, 05:14 PM

Measured from the face of the fingers where the throw out bearing rests against to the top of the hub on the clutch disc, and it is ~0.29" of throw before the throwout hits the clutch disc.

**UltimatE** · 11-05-2009, 06:56 PM

Alright I pulled the clutch off the flywheel and got some side to side pictures with the old clutch.

I placed 2 2x4's on my workbench to simulate the flywheel surface, and used the bench as a measuring point. So if you take the difference of these two measurements, it would be how much closer the new disc hub is to the pressure plate fingers.

With the caliper I measured 2.25" on the stock AX-5 clutch, and 2.675" on the '84 camaro clutch. So we're talking a good 0.425 LESS clearance for the throw out bearing to move.

**UltimatE** · 11-05-2009, 07:33 PM

And here's just a fun pic for you guys. I had an old clutch tool from my previous wrangler, an '88 with the BA 10/5. The input shaft matches -- 10 spline on a 1.125" diameter, however the pilot bearing was the smaller 0.59". What else would I do except use duct tape to make up the difference to 0.75" ? This thing has worked flawlessly twice now

Redneck engineering baby.

**UltimatE** · 11-05-2009, 09:11 PM

You guys think that 0.425" of lost clearance is my issue? I was very surprised to find out 2/3rds of my throw out bearing clearance was gone with the new clutch disc.

**Opihi59** · 11-05-2009, 10:08 PM

I think you have found what the problem is. You may be able to remove that extra length on the clutch spline hub with a cutoff wheel, then finish off with an angle grinder, then de-bur the splines and see how it goes. Remember, that pressure plate only pulls back a small amount, likely the extra length on the spline hub is the holdup that restricts travel.

moonshinefuel · 11-06-2009, 12:22 PM

Where did you get that disc? I have not seen that version I don't think. This is the one i have and how it fits on the flywheel, with much less of a center hub on the side that faces the pressure plate.
I have not tightened down the pressure plate on bottom pic, but just wanted to place it on there.

**UltimatE** · 11-06-2009, 12:30 PM

Its a disc I got from Autozone supposedly for a 1984 camaro with the 4cyl and 4-speed manual.

I was given a NAPA Part # RCF584 from czjeeper for a 9.125" diameter clutch disc with 10 splines on a 1.125" diameter. This clutch was used, as a reference, in early CJ5's with the 2.5L engine (1983 CJ5 with the 4cyl) That is the disc he used and works just fine.

What application / part number is your disc?

moonshinefuel · 11-06-2009, 12:33 PM

Quote:

Originally Posted by UltimatE

Its a disc I got from Autozone supposedly for a 1984 camaro with the 4cyl and 4-speed manual.

Wow, yea I do not like the look of it at all. I think your post/conversion will most likely be the example of which clutch disc to avoid.

**UltimatE** · 11-06-2009, 12:44 PM

Quote:

Originally Posted by moonshinefuel

Wow, yea I do not like the look of it at all. I think your post/conversion will most likely be the example of which clutch disc to avoid.

I remember seeing a mention of the 84 camaro clutch in reading some of the writeup/posts... I guess that's out of the question now. Maybe it will work with the Dakota clutch setup because of the much larger pressure plate?

Either way I updated my previous post with more information and a quick question.