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.
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.
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?
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.