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Unread 10-31-2013, 11:44 AM   #1
pagnani
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Clutch Pedal is dead?

I tried to search a bit and was hoping had some basic instructions for a begginner. I was driving my CJ this morning and all the sudden I went to press my clutch in to shift and it went straight to the floor with no resistance. I could bounce it up and down. I had to force it out of gear into neutral so I could park it safely. Where do I go from here? Some are saying its a cable? but I cannot see anything like that in my searches. Thanks in advance for your help and suggestions. (83 CJ7, 258 with t5)

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Unread 10-31-2013, 11:54 AM   #2
pagnani
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Here is a quick video of what has happened.

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Unread 10-31-2013, 12:01 PM   #3
Texian
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Looks like your clutch adjustment rod came loose. The one that goes to the clutch fork coming out of the bell housing.

Check at bellcrank too.
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Unread 10-31-2013, 01:03 PM   #4
SLO_Ken
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That used to happen to me all the time. The bellcrank pivots and bushings had worn out, and the engine side of the bellcrank would come off its pivot. I solved the problem by replacing the bushings and putting a spring between the bellcrank and the body side pivot, to push the bellcrank onto the engine side pivot. No problems since...
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Unread 10-31-2013, 02:54 PM   #5
pagnani
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Quote:
Originally Posted by SLO_Ken View Post
That used to happen to me all the time. The bellcrank pivots and bushings had worn out, and the engine side of the bellcrank would come off its pivot. I solved the problem by replacing the bushings and putting a spring between the bellcrank and the body side pivot, to push the bellcrank onto the engine side pivot. No problems since...
Is there any chance you have a picture of that setup?
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Unread 10-31-2013, 02:57 PM   #6
SLO_Ken
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Not with me. I can probably get a couple shots when I get home from work this evening...
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Unread 10-31-2013, 02:58 PM   #7
mastercraftka
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Just check the linkage first, mine has done this before just popped loose. Then go from there to the clutch fork.
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Unread 10-31-2013, 05:31 PM   #8
LumpyGrits
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IF this is the case. You have either bad tranny mounts or engine mounts that are allowing movement.
Bellcrank is also a known problem area.
LG
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Unread 11-01-2013, 03:01 AM   #9
keith460
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Your mechanical clutch linkage should look like what is pictured. The rod end is an improvement over stock item.

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Unread 11-01-2013, 07:29 AM   #10
82JeepCJ7
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I cheat

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Unread 11-01-2013, 07:46 AM   #11
Ken4444
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That linkage area is very easy to work on as long as you have a light, some basic hand tools, and some mechanical knowlede. The actual rod (shown in Keith's photo) can be adjusted longer or shorter by screwing the end forward or backward. That's the first thing to do: make sure that rod is in place and adjusted so it doesn't fall out at the clutcn fork end. If you still have problems, the bellcrank comes out with 4 bolts if needed, and you can examine that for wear or problems. These parts are all available new (and used) if needed.

The big problem with the design is that there is no concrete attachment to the clutch throwout fork. It is designed this way to allow the transmission to move twist/turn slightly when the engine revs. That's where a hydraulic clutch comes in handy: The hydraulic lines can flex when the transmission moves, and this allows the business end to be firmly bolted to the throw out fork somehow, so it can't fall off.
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Unread 11-01-2013, 08:06 AM   #12
Matt1981CJ7
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Adding to Ken's good advice...

Your clutch pedal should have around 1-1/4" free-play before you feel resistance, when the adjustable arm is set correctly.

Matt
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Unread 11-01-2013, 10:27 AM   #13
pagnani
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Thank you for all the advice. I was just looking at Keith's picture in another thread. I crawled under it this morning and saw I was missing something. After looking around for a few minutes, I found this.
image-2439847539.jpg

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Unread 11-01-2013, 10:29 AM   #14
mastercraftka
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Yep like I said linkage, but someone had good advice it my be caused by the engine torqueing too much might want to check your motor mounts and your bolts on the bell housing.

Just glad you figured it out.
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Unread 11-01-2013, 11:59 AM   #15
Ken4444
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Quote:
Originally Posted by pagnani View Post
Thank you for all the advice. I was just looking at Keith's picture in another thread. I crawled under it this morning and saw I was missing something. After looking around for a few minutes, I found this.
It looks like the curved end sheared off. Mine was in a similar state, but the metal was only 1/2 worn through. I could have welded the gap closed but I ended up just replacing the part with a new one. I still have the old worn part in my tool bag, just in case.

Here's the replacement part at Quadratec.

You will see it's a slightly improved design from the original part.
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Last edited by Ken4444; 11-01-2013 at 12:00 PM.. Reason: Dang typos.
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