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Unread 08-31-2011, 08:40 AM   #1
stenyeart
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Clutch Issue

1990 YJ
Swapped in a 4.0L from 1996 XJ. Converted the motor from AW4 setup to an AX15 setup.

Installed new clutch disc, pressure plate, pilot bearing, clutch fork, throwout bearing and sealed master/slave setup during the swap.

I have been working on several things during this swap so the clutch components have sat in the engine for roughly two years.

I got the motor running a couple of months ago and the clutch was working great. I drove the Jeep around a little (around 10 miles). The only shifting issue I had was getting it into reverse. Read online about putting it into first and then reverse and almost eliminated the grinding.

One day, I drove it to the parts store and just as I was getting there it was starting to get hard to get into gear. I had to force it when I was shifting.
On the drive home, I couldn't get it into gear while it was running. I could grind it into reverse, but as soon as I got it into gear, the Jeep rolled.

If I start it in gear it wants to take off with the clutch pedal down.

I can shift it through all the gears with the engine off.

To get it home, I started it in gear, but I couldn't rev match to shift. It wouldn't let me pull it out of gear, so I crawled it home in second gear.

I checked the fluid in the master cylinder and it was full. I pulled the slave cylinder and bled it by pointing the push rod towards the ground and pumping it. Still no change. Bled the slave again. No change. The whole time I have had good resistence on the clutch pedal.

I am thinking it is the master/slave, but wanted a second opinion before I ordered a new one. My concern is that I wasn't able to pull it out of gear while it is running. I am running 10w30 in the AX15 and am wondering if I shouldn't change it to redline or penziol syncromesh.

Forgot to mention that double clutching does not help.

Any input would be appreciated, its not my daily driver, but I would like to get it going.

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Unread 08-31-2011, 10:20 AM   #2
Matt24138
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Don't push the pedal with the slave open when you release it you suck air in. Gravity bleed. Get a hose that runs from the bleeder into a cup full of fluid. Leave the cap on the master let it run into the cup close the screw open the master fill and repeat. Try bleeding that way a few times see if it helps.
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Unread 08-31-2011, 11:31 AM   #3
stenyeart
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I have the external slave setup that is sealed, it does not have a bleeder.

I am thinking that my problem is in the hydraulics, I am not sure if there is something internally that could be causing my issues.

Today I took the slave cylinder off and held the pushrod with on hand and pushed the clutch with the other. It seems like it has good throw and force, but I do not know what a good one feels like or if you can even tell anything by doing this.

Anyone think of anything I should check before I get a new master/slave combo?
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Unread 08-31-2011, 11:52 AM   #4
Matt24138
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Ok. Then try this. Take the cap off the master and pump the pedal about 100 times. Seriously 100 times. Check it.
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Unread 08-31-2011, 12:43 PM   #5
stenyeart
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That was fun.

Still no improvement.

Any other ideas?
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Unread 08-31-2011, 02:08 PM   #6
Matt24138
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You don't see any leaks on the firewall or inside behind the pedal or at the slave?
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Unread 08-31-2011, 02:29 PM   #7
stenyeart
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No leaks and the fluid level is good.
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Unread 08-31-2011, 02:33 PM   #8
Matt24138
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My fluid level was good but I had a pin hole big enough to let air in. Is the fluid black? Might need to get bigboss on this one.
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Unread 08-31-2011, 03:25 PM   #9
1SASjeepster
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Tell me about your throwout bearing assembly... what type is it? How did you put it on? Do you use a throwout bearing arm with your hydraulic assembly or is it entirely hydraulic?

Take care,
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Unread 08-31-2011, 05:08 PM   #10
stenyeart
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The throwout bearing rides in the clutch fork. The clutch fork is installed on a pivot point on the Passengers side and is driven by the external slave cylinder on the Driver's side.

I will have to check the color of the fluid when I get home.
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Unread 08-31-2011, 08:42 PM   #11
1SASjeepster
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Your description of the problem sounds like it is throwout bearing/arm related. Assuming the transmission is fine, I would first check the throwout bearing, the pivot and the spot welded clip that holds the throwout bearing onto your input shaft (or more correctly the input shaft collar.) This could happen gradually or all of a sudden.

Take care,
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Unread 08-31-2011, 10:06 PM   #12
Raindem
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It probably isn't causing your problem but I'd get rid of the 10w-30 oil.
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Unread 09-01-2011, 12:11 AM   #13
GottaYJ
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10w30 is recommended for the trans
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Unread 09-01-2011, 09:56 PM   #14
Raindem
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Quote:
Originally Posted by GottaYJ View Post
10w30 is recommended for the trans
Negative. The factory service manual recommends 75w-90. Personally, I run Redline MT-90.
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Unread 09-01-2011, 11:07 PM   #15
GottaYJ
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Read up Raindem
http://www.jeepforum.com/forum/f12/b...change-865520/
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ax15 , clutch problem , shifting issues , shifting problem , slave cylinder

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