installed clutch kit, clutch won't disengage - JeepForum.com
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post #1 of 27 Old 08-20-2017, 03:33 PM Thread Starter
chesterm64
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installed clutch kit, clutch won't disengage

1989 wrangler, 2.5L with ax5 and internal slave. I installed a LUK kit (including pilot bearing, clutch disk, pressure plate and internal slave cylinder) and bled the system using gravity method, vacuum and pump and bleed. Pedal seems about normal (kind of soft). I can run the gears with engine off, but with engine on and clutch pedal pushed in, I get grinding in reverse and when I push in on forward gears the jeep tries to move forward but won't go into gear. Almost feels like the straps did not release from the slave cylinder? Or are these symptoms of the clutch disk being reversed? Tried to make sure I got it the right way, but I had to install disk a couple of times before I got it centered correctly.

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post #2 of 27 Old 08-20-2017, 05:45 PM
Drednot
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That's usually the sign that the disc is in backward
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91 YJ Sahara, 4.0L, AX-15/NP231, D30/D35@3.07
12 Cherokee 4x4,3.7L,42RLE/MP1522, D30M/8.25@3.73
Emission test=YES
"Non Vi Sed, Arte"
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post #3 of 27 Old 08-24-2017, 05:18 PM Thread Starter
chesterm64
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Well, it was installed correctly. Upon further inspection of the clutch disc, it appears to not be the same. The disc that came out was a SACHS 1862292001 53007584 and the LUK kit I bought had a LUK 323029810. The SACHS disc appears to have about a 0.5 inch protrusion on each side of the disc where the spline goes through and the LUK disk has about a 1 inch protrusion only on the flywheel side. Am I screwed on the whole kit or can I just buy a correct clutch disc? The pilot bearing works and the two pressure plates seem to be the same and the slave cylinder looks ok too.
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post #4 of 27 Old 08-25-2017, 01:01 AM
Drednot
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Quote:
Originally Posted by chesterm64 View Post
. Am I screwed on the whole kit or can I just buy a correct clutch disc?
Id start by asking the guys you bought it from to make it right. See if the friction disc is available separately

91 YJ Sahara, 4.0L, AX-15/NP231, D30/D35@3.07
12 Cherokee 4x4,3.7L,42RLE/MP1522, D30M/8.25@3.73
Emission test=YES
"Non Vi Sed, Arte"
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post #5 of 27 Old 08-25-2017, 08:41 AM Thread Starter
chesterm64
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Well, everywhere that I can check says that the LUK 01-033 clutch kit is a fit for the 89 wrangler with 2.5L. I'm starting to think my engine may not match an 89 wrangler. It has a remanufactured sticker on the side of the block. I suppose it could be from a later year and also has a later year flywheel? I guess I need to pull the flywheel and try to verify the part number on it.
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post #6 of 27 Old 08-25-2017, 12:53 PM
Drednot
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can you read the engine serial number? Its on a machined pad on the passenger side of the block near the distributor cap

91 YJ Sahara, 4.0L, AX-15/NP231, D30/D35@3.07
12 Cherokee 4x4,3.7L,42RLE/MP1522, D30M/8.25@3.73
Emission test=YES
"Non Vi Sed, Arte"
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post #7 of 27 Old 08-25-2017, 03:19 PM Thread Starter
chesterm64
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cast in number on the block is: 53005532 with what looks like a 9I-2HXI5 hand-stamped in the area above it. There may be more of the hand stamped number, it is partially behind the dipstick support.

also has REMANUFACTURED ENGINE sticker with Production No. 817871
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post #8 of 27 Old 08-25-2017, 08:26 PM
Drednot
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Quote:
Originally Posted by chesterm64 View Post
with what looks like a 9I-2HXI5 hand-stamped in the area above it. There may be more of the hand stamped number, it is partially behind the dipstick support
The cast number doesnt really help. The stamped number is the one. Is there actually a dash after the 9I , or just a gap?

91 YJ Sahara, 4.0L, AX-15/NP231, D30/D35@3.07
12 Cherokee 4x4,3.7L,42RLE/MP1522, D30M/8.25@3.73
Emission test=YES
"Non Vi Sed, Arte"
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post #9 of 27 Old 08-25-2017, 09:00 PM Thread Starter
chesterm64
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on second look I think it is just a gouge and not a dash. I think the code is December 15 of 1989. Which leaves me wondering why everyone believes the LUK 01-033 kit fits an 1989, when the offset on the clutch disc is so different from what came off.
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post #10 of 27 Old 08-26-2017, 03:58 AM
Drednot
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You are correct on the engine ID.
Which transmission do you have? AX5, correct? There were three transmissions that year. The AX5, the AX15, and the B/A10-5. I'm wondering if there is a discrepancy in the parts catalog, or the wrong disc in the box?

91 YJ Sahara, 4.0L, AX-15/NP231, D30/D35@3.07
12 Cherokee 4x4,3.7L,42RLE/MP1522, D30M/8.25@3.73
Emission test=YES
"Non Vi Sed, Arte"
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post #11 of 27 Old 08-26-2017, 06:47 AM Thread Starter
chesterm64
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I was able to consult a SACHS catalog and determined that the K1914-03 kit should fit an 1989 wrangler with 2.5L. I'm still a little gun-shy and would like to cross-reference the clutch disc number that I took off to the kit, but have not found a way to do that yet. I haven't found anyone who sells this SACHS kit in their store, so it'll have to be an online order (roll the dice). I'll try to return the LUK kit or just keep it for a spare slave cylinder.

Thanks for the help
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post #12 of 27 Old 08-26-2017, 07:28 PM Thread Starter
chesterm64
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I'm still having a problem with why the LUK 01-033 clutch kit did not work. I've talked to several people who have told me this is the correct kit for a 1989 wrangler with 2.5L engine. After looking it over some more today, the only thing I see that could be causing interference is the amount of protrusion of the spline housing on the flywheel side of the LUK disc. Anybody have any thoughts on whether this could cause the interference? Trying to add images - hope it works.


LUK disc -flywheel side


LUK disc - pressure plate side


SACHS disc - flywheel side


SACHS disc - pressure plate side
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post #13 of 27 Old 08-26-2017, 07:37 PM Thread Starter
chesterm64
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try again on images

LUK disc -flywheel side


LUK disc - pressure plate side


SACHS disc - flywheel side


SACHS disc - pressure plate side
https://ibb.co/gYrPe5
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post #14 of 27 Old 08-26-2017, 07:46 PM Thread Starter
chesterm64
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IMG tag did not work very well, so attaching pictures directly

1st picture is SACHS disc - flywheel side
2nd picture is LUK disc - pressure plate side
3rd picture is LUK disc - flywheel side
4th picture is SACHS disc - pressure plate side

My problem is - I know the SACHS disc worked so why is it so different on the spline housing offsets from the LUK?
Attached Thumbnails
IMG_20170824_165923625 (1).jpg   IMG_20170824_165941166 (1).jpg   IMG_20170824_165945368 (1).jpg   IMG_20170824_165929066 (1).jpg  
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post #15 of 27 Old 08-27-2017, 07:57 AM Thread Starter
chesterm64
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OK, I think I've been running myself in circles with this clutch disc. The new LUK clutch disc fits flat against the flywheel, so that is as far forward as it will ever go, and therefore there can't be any interference because of the spline housing.

That leaves the slave cylinder. It must push the fingers to disengage the clutch and allow the gears to be shifted while the flywheel is turning. If the clutch won't disengage, it must be the fault of the slave cylinder or not getting air out of the system. I'm wondering if I should release the straps on the slave cylinder and pre-fill it with fluid before assembling the transmission back.

I also wonder if I should go with a better slave cylinder than the one that came with the LUK kit?
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