Official 4.0 swap thread - Page 24 - JeepForum.com
Reply
 
LinkBack Thread Tools
post #346 of 429 Old 08-06-2013, 03:30 PM
Skerr
Registered User
1985 CJ7 
 
Join Date: Sep 2008
Location: White Springs
Posts: 9,399
Has anyone had problems with the clutch not working after the swap? I either slept through that part of this swap, or I skipped over it, but I never saw where anyone had this problem. My clutch fork is hitting the back edge of the square window in the bellhousing. In other words, you can't depress the clutch pedal far enough to activate the clutch. The reason for this is the 4.0 flywheel is 400/1000s thinner than the 258 flywheel. This allows the throwout bearing to sit farther back. I have searched for a longer TO bearing, but to no avail. Novak makes one, but they are retooling, and they are at least two weeks away before running them. The other option is an adjustable pivot ball.

Where did I go wrong? What did you guys do to avoid this problem?

We are using an XJ 4.0, XJ manual flywheel, modified 258 bellhousing (for CPS), T18 tranny, diaphragm clutch set.


Kerrdog
Go Fish! <*////><

But the right word at the right time... "Hey, give me a little hug!" That's the difference between lightning and a harmless lightning bug!
Skerr is offline  
Sponsored Links
Advertisement
 
post #347 of 429 Old 08-07-2013, 05:17 AM
NelsonATC
Registered User
1980 CJ7 
 
Join Date: May 2009
Location: Warwick, RI
Posts: 423
My initial thought is that something is missing. That small of a variation in the thickness of the flywheel should not translate to the clutch fork hitting, and meeting a longer throwout bearing.

Is it possible that you either forgot to put in the pivot ball behind the clutch fork, or it fell out? I usually use JB Weld, or epoxy, to hold them in place while I am positioning everything. It doesn't last forever, but by the time the epoxy lets go, the ball is firmly seated behind the clutch fork and won't go anywhere.

As far as getting a larger throw out bearing, take your current throwout, bring it to the parts store, and find something a little longer. They do make them for various applications.

I am running a T176 and a 4.0 flywheel, and had no issues.

Mike
1980 CJ7
NelsonATC is offline  
post #348 of 429 Old 08-07-2013, 03:41 PM
Skerr
Registered User
1985 CJ7 
 
Join Date: Sep 2008
Location: White Springs
Posts: 9,399
Quote:
Originally Posted by NelsonATC View Post
My initial thought is that something is missing. That small of a variation in the thickness of the flywheel should not translate to the clutch fork hitting, and meeting a longer throwout bearing.

Is it possible that you either forgot to put in the pivot ball behind the clutch fork, or it fell out? I usually use JB Weld, or epoxy, to hold them in place while I am positioning everything. It doesn't last forever, but by the time the epoxy lets go, the ball is firmly seated behind the clutch fork and won't go anywhere.

As far as getting a larger throw out bearing, take your current throwout, bring it to the parts store, and find something a little longer. They do make them for various applications.

I am running a T176 and a 4.0 flywheel, and had no issues.
Thanks, Nelson. The pivot ball is in place, and I have no explanation for this malady! There is more to this story, but I won't post it up here. It can be read in Clay's Build Thread... the last few pages. Going with an adjustable ball stud. I will keep ya'll posted.

Kerrdog
Go Fish! <*////><

But the right word at the right time... "Hey, give me a little hug!" That's the difference between lightning and a harmless lightning bug!
Skerr is offline  
post #349 of 429 Old 08-07-2013, 05:12 PM
Matt1981CJ7
Web Wheeler
 
Matt1981CJ7's Avatar
1981 CJ7 
 
Join Date: May 2011
Location: Elbert
Posts: 16,348
Quote:
Originally Posted by NelsonATC View Post
My initial thought is that something is missing. That small of a variation in the thickness of the flywheel should not translate to the clutch fork hitting, and meeting a longer throwout bearing.
Assuming Scott's measurements are accurate, the 4.0 flywheel is nearly 7/16" thinner then the 258's.

That's not a "small variation" in my book.

Matt
Matt1981CJ7 is offline  
post #350 of 429 Old 08-07-2013, 06:24 PM
Skerr
Registered User
1985 CJ7 
 
Join Date: Sep 2008
Location: White Springs
Posts: 9,399
Quote:
Originally Posted by Matt1981CJ7 View Post
Assuming Scott's measurements are accurate, the 4.0 flywheel is nearly 7/16" thinner then the 258's.

That's not a "small variation" in my book.

Matt
Matt, it's 400/1000s, so .4".

Kerrdog
Go Fish! <*////><

But the right word at the right time... "Hey, give me a little hug!" That's the difference between lightning and a harmless lightning bug!
Skerr is offline  
post #351 of 429 Old 08-07-2013, 06:24 PM
billybooster2
Registered User
1983 CJ8 
 
Join Date: Jul 2008
Location: Cow Mountain
Posts: 1,122
That makes it 80% of 1/2 inch!
billybooster2 is offline  
post #352 of 429 Old 08-07-2013, 07:54 PM
row684
Registered User
1984 CJ7 
 
Join Date: Sep 2008
Location: Logan
Posts: 747
Or 2/5ths of an inch if you reduce 400/1000ths completely.
row684 is offline  
post #353 of 429 Old 08-07-2013, 08:02 PM
billybooster2
Registered User
1983 CJ8 
 
Join Date: Jul 2008
Location: Cow Mountain
Posts: 1,122
Round it up to a furlong
billybooster2 is offline  
post #354 of 429 Old 08-08-2013, 06:48 AM
Matt1981CJ7
Web Wheeler
 
Matt1981CJ7's Avatar
1981 CJ7 
 
Join Date: May 2011
Location: Elbert
Posts: 16,348
Quote:
Originally Posted by Skerr View Post
Matt, it's 400/1000s, so .4".
So it's a hair under 7/16". Correct?

Or has my grade school mathematics failed me?

Matt
Matt1981CJ7 is offline  
post #355 of 429 Old 08-08-2013, 10:01 AM
NelsonATC
Registered User
1980 CJ7 
 
Join Date: May 2009
Location: Warwick, RI
Posts: 423
Okay, I'll give you that.

But something is amiss with the flywheel. Mine did not have any impactful variation in thickness on my setup. I used a flywheel from a 99 TJ that I had resurfaced.

Mike
1980 CJ7
NelsonATC is offline  
post #356 of 429 Old 08-08-2013, 12:42 PM
SLO_Ken
Registered User
1986 CJ7 
 
Join Date: Nov 2009
Location: California
Posts: 1,021
Quote:
Originally Posted by NelsonATC View Post
Okay, I'll give you that.

But something is amiss with the flywheel. Mine did not have any impactful variation in thickness on my setup. I used a flywheel from a 99 TJ that I had resurfaced.
I agree. I used a new Luk flywheel when I did mine a few months ago. I definitely think I would have noticed almost 1/2" difference in thickness. That's close to 30%!
SLO_Ken is offline  
post #357 of 429 Old 08-08-2013, 03:59 PM
Skerr
Registered User
1985 CJ7 
 
Join Date: Sep 2008
Location: White Springs
Posts: 9,399
Quote:
Originally Posted by billybooster2 View Post
That makes it 80% of 1/2 inch!
Quote:
Originally Posted by row684 View Post
Or 2/5ths of an inch if you reduce 400/1000ths completely.
Quote:
Originally Posted by billybooster2 View Post
Round it up to a furlong


Quote:
Originally Posted by Matt1981CJ7 View Post
So it's a hair under 7/16". Correct?

Or has my grade school mathematics failed me?

Matt
Sorry Matt. It was dumb to correct you. It just goes to show my state of mind. I wasn't thinking!

Thanks for the smile Gentlemen!

Kerrdog
Go Fish! <*////><

But the right word at the right time... "Hey, give me a little hug!" That's the difference between lightning and a harmless lightning bug!
Skerr is offline  
post #358 of 429 Old 08-11-2013, 03:13 PM
Gigemags05
Registered User
1980 CJ7 
 
Join Date: Oct 2012
Location: Denton
Posts: 658
Quote:
Originally Posted by Gigemags05
I completed this swap using the hesco cps relocation kit. Now, I think my cps is going out. Does anyone know if I can use an after market cps from the parts store or do I have to replace it with a hesco cps?
I replaced the cps and am still having the issue. The jeep starts and runs fine then suddenly dies.

It looks like its throwing code 73 and 75, but I can't find those anywhere for a 1992 4.0

I'm at a complete loss.
Gigemags05 is offline  
post #359 of 429 Old 08-11-2013, 03:42 PM
NelsonATC
Registered User
1980 CJ7 
 
Join Date: May 2009
Location: Warwick, RI
Posts: 423
I had a similar problem with a friends rate down the trail the other day. He has an early 90's XJ. The problem ended up being the ballast resistor. Once we bypassed it, he had no other problems.

I eliminated the ballast resistor when I send out my wiring harness, but if for some reason you kept yours ( and you used an XJ harness), that may be the problem.

Mike
1980 CJ7
NelsonATC is offline  
post #360 of 429 Old 08-11-2013, 03:51 PM
Gigemags05
Registered User
1980 CJ7 
 
Join Date: Oct 2012
Location: Denton
Posts: 658
My harness is from hesco and they eliminate the ballast resistor.

The fuel pump primes and seems to be in good working order.
Gigemags05 is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
Official AMC V8 swap thread BLS33 Jeep CJ Forum 493 03-30-2016 11:57 PM
Official Cummins 4BT Swap Thread for CJ-7's BigTorqueCJ Jeep CJ Forum 319 09-23-2014 06:29 PM
Official Engine/Assembly/everything else thread jagerlager Jeep CJ Forum 162 10-31-2010 08:30 PM
Official AMC V8 swap thread/Need more imafishingfred Jeep CJ Forum 11 10-21-2007 05:43 PM
Official CJ Lift Thread webejpn01 Jeep CJ Forum 1 10-06-2006 07:59 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome