Greetings...and Cj5 Clutch Issue

Well… I finally have the old retractable cable guide (pictured above) removed from the mounting bracket and started to finish connecting the ball-end of the the adjuster to the t/o fork. However, I'm about a 1/2 inch too short of the socket (??). No matter what I do I can't get them to come together. Any thoughts?

 

Was the replacement cable the same overall length?
Should be around 58-1/4" long.
Maybe the hack bracket on the transfer case is to blame?

 

I would believe this to be the problem..

 

Thanks for your input fellas. I/we finally ended up finally getting the cable installed by reversing the installation sequence --- removing it where it attaches at the clutch pedal control arm and attaching it first to the t/o fork and then to the control arm. I cant believe I didn't try that sooner...

However...the new clutch cable had NO effect. After installation, I attempted a test-drive and didn't even get out of the driveway. I could have, but I wouldn't have gotten very far. As soon as I attempted to shift in reverse there was a subtle grind before it went into gear. I knew immediately it was 'back to the drawing board'. So I decided to just let the Jeep run and experiment with a few gear sequences to see what would happen. Here's how it played out:

• Pushed clutch, attempted reverse -- big grind. All other gears fine. Back to neutral.
• Sat for a minute, pushed clutch, attempted reverse -- big grind. Al other gears fine (1st would catch only slightly). Back to neutral.
• Sat for a minute, pushed clutch, attempted reverse -- big grind. Back to neutral. Pushed clutch, counted 5 seconds (with clutch in) attempted reverse -- no problem. Back to neutral.
• Sat for a minute, pushed clutch, counted 3 seconds (with clutch in), attempted reverse -- no problem. Back to neutral.
• Sat for a minute, pushed clutch, counted 2 seconds (with clutch in), attempted reverse -- very slight grind. Back to neutral.
• Sat for a minute, pushed clutch, immediately attempted reverse -- big grind.

This same sequence with all other gears revealed little if any problem.

So...my tiny mind concludes that my clutch is dragging, possibly the pilot bearing has failed or the clutch disk is warped. Would love to have some much greater minds weigh in on this for me. Thanks...

 

Update: I think I may have isolated the issue above to inadequate adjustment on the new clutch cable. I tightened the cable a few more turns this morning to make the clutch release earlier, and the test drive that followed went smoothly (though I still need to pause with the clutch pedal in for a couple of seconds before selecting reverse). I'm hoping I haven't tightened the cable too far -- I have about an inch or so of play in the pedal.

 

This is normal. You must disconnect from the engine and wait for the gears to stop spinning before you engage reverse. Forward gears are synchromesh type and will match speeds as they mesh and not clash.

 

X2. What Howard said.

 

Thanks again, gents. This has been a real learning process for me and I have deeply appreciated everyone's thoughtful input. Cant thank you all enough...
Howard/Tim: I've adjusted the cable down to "1/2" - "3/4" inch. Thanks.

 

My T 90 has no synchronizers in first or reverse, so out of habit I put it in second to stop the trans from spinning and then go to reverse, works for me anyway. Good Luck.

 

Rick: I started implementing your suggestion today. Seems to work well! Thanks for the tip.