[dmask0]

I've got a '77 CJ5 with a 304 and the T150. The T150 was toast so I picked up a replacement. While making the swap I also replaced the clutch (TO bearing, pressure plate, clutch plate and pilot bearing). When I finally got everything bolted back up, I adjusted the mechanical clutch linkage and noticed that the threads had to be turned all the way out in order to get the clutch pedal fully extended back up. The rod is turned to the very last threads and is as long as you can possibly make it.

The clutch that I replaced was in good shape (didn't really need to be replaced but didn't know until I got in there) and the linkage rod was adjusted about halfway down the threads for the old clutch kit.

And if that wasn't enough of a concern, when I started her up there is some ticking coming from the clutch when the pedal is pressed. When you're not touching the clutch pedal - it sounds fine - no noises. The moment i rest my foot on the clutch pedal and put the slightest pressure on it - there is ticking coming from the clutch/trans area. The clicking continues while pressing pedal all the way down and doesn't stop until removing foot from pedal.

It shifts fine and the new transmission is great. I'm just worried about the ticking noise and the excessive clutch rod adjustment. It's such a bummer when you spend all weekend doing something and get it wrong. Hopefully someone might know what I can adjust. And I didn't completely remove the clutch linkage - I just pulled the two bolts that hold it to the bellhousing - so I know the linkage is properly installed. Thanks, everyone.

[bum4x4]

I don’t mean to hijack your thread but mines the same way, when I changed out the 258 for a 304 I had to adjust the linkage all the way out, mine makes a rattling noise when I apply light pressure to the clutch pedal also. The only different is when my jeep warms up with in town driving ( a lot of stop & go driving ) my clutch gets harder to shift in 1st & reverse. I hope someone knows what’s the problem might be.

[dmask0]

is it possible that i put the throwout bearing on backwards in a fit of delirium?

that's the only thing i can think of. it would require the linkage to be lengthened since the width of the TO bearing would be missing. and maybe the pressure plate forks would click against the tabs on the backside of the TO bearing.

maybe the 90 degree heat and all the rust dropping into my eyes got the best of me and i put it in backwards. oh man i don't want to pull that transmission/tcase again.