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Unread 03-05-2013, 09:18 PM   #1
444
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What is wrong with my clutch!?! (external slave swap)

Ok, I swapped to an external slave setup on my ax-15 and swapped in a 5.2 magnum using a dakota ax-15 bellhousing. Everything bolted up nicely. Problem is my clutch. 88 YJ, brand new master cyl, hose and slave. I go to put the slave cylinder in and the piston does not reach the clutch fork! Even after snapping the plastic tabs, the piston at it's full extension does not reach the clutch fork. The clutch fork pivot is there and in good shape and the clutch fork seems to be seated on it properly. Clutch, pressure plate, throw out bearing all seems to be in there properly and it starts up and runs with no strange noises. But the slave cylinder is preventing me from test driving!

Any ideas? I didn't think I needed to use a dakota slave, afaik other guys used the jeep slave. I don't know what to do, other than maybe weld an extension onto the piston.

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Unread 04-04-2013, 04:31 PM   #2
doublins
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Bump because I'm about to do a 5.9 w/ ax-15 and this interests me as well
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Unread 04-04-2013, 04:33 PM   #3
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What flywheel did you wind up using, and were you able to mount tranny in stock location?
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98 Sahara 5.2L Magnum V8
Long Arms, 35x12.5 BFGs
Ford 8.8/4.88s

My Magnum V8 Build Thread:
http://www.jeepforum.com/forum/f22/m...rings-1516649/
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Unread 04-04-2013, 04:42 PM   #4
5-90
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Quote:
Originally Posted by 444 View Post
Ok, I swapped to an external slave setup on my ax-15 and swapped in a 5.2 magnum using a dakota ax-15 bellhousing. Everything bolted up nicely. Problem is my clutch. 88 YJ, brand new master cyl, hose and slave. I go to put the slave cylinder in and the piston does not reach the clutch fork! Even after snapping the plastic tabs, the piston at it's full extension does not reach the clutch fork. The clutch fork pivot is there and in good shape and the clutch fork seems to be seated on it properly. Clutch, pressure plate, throw out bearing all seems to be in there properly and it starts up and runs with no strange noises. But the slave cylinder is preventing me from test driving!

Any ideas? I didn't think I needed to use a dakota slave, afaik other guys used the jeep slave. I don't know what to do, other than maybe weld an extension onto the piston.
Did you swap the front bearing retainer on the transmission? The "internal" version is just a plate, the "external" version has a sleeve that the T/O bearing rides on. Without that sleeve, there's too much radial play under the bearing ID, and it won't be able to travel out far enough to disengage the clutch.

(In case you hadn't guessed, this is not the first time I've heard of this difficulty.)
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