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Novak Clutch

Discussion in 'Builds and Fabricators Forum' started by shaun, Sep 16, 2020.

  1. Oct 1, 2020
    shaun

    shaun Member

    Lebanon, Ohio
    Joined:
    Oct 15, 2015
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    390
    Transfer case is disengage what’s weird is my TC and High Low sticks seem off. On my middle stick it 2 position and my high low is 2 position. Is this right? Also I threaded the Novak plunger all the way back and still same problem. Won’t go into first(grinds) and easy into 2nd. But doesn’t move or stall if taking foot off brake and clutch.
     
  2. Oct 1, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    High/low has neutral in the middle, maybe that’s why it’s not engaging? E30C83B8-232F-4669-93DD-286F3CB6632A.jpeg
     
  3. Oct 1, 2020
    shaun

    shaun Member

    Lebanon, Ohio
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    Oct 15, 2015
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    So if my TC is out, then high and low shouldn’t matter right?
     
  4. Oct 1, 2020
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    Did you try to start it in 1st with the clutch pushed in? (not in the garage please).
    you get nothing in second- did you try 3rd?
    shift that TC all around to every combo you can until you get some feedback.
    If no response from TC shifting I'd think the TC is blown up somehow. Its not very hard to swap and I'm sure there is a member here who has a spare. Post a WTB for that.
     
  5. Oct 1, 2020
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
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    Mar 4, 2003
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    5,466
    Interlock Pill - regulates what positions are available in the "STOCK" D18 Tcase.

    If your Tcase is "out" (meaning two wheel drive - power to rear drive shaft only), you only have Neutral and High to pick from.
    If your Tcase is "in" (meaning four wheel drive - power to front AND rear drive shafts), you have Low, Neutral, and High to pick from.

    Many cases have had the interlock pill removed so they can operate in Two Wheel Drive Low... and that's the ONLY way it would work to get that combo.
     
  6. Oct 1, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    It would matter if your transfer case was in neutral, that wouldn’t allow power to the wheels in 2wd or 4wd. Just make sure you’re out and In high. Those shifters can be a pain in the butt sometimes to get engaged, rolling the Jeep a little can help.
     
  7. Oct 2, 2020
    shaun

    shaun Member

    Lebanon, Ohio
    Joined:
    Oct 15, 2015
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    390
    I’m lost. I tried the TC in disengage-neutral/high, got it into second only as normal. Moved the Hydraulic slave plunger all the way back and to the middle. Just enough before the TO bearing touches the clutch fingers, still same thing happens. Everything worked before I tore it apart and did any mods. My mind is boggled. I’m almost thinking about taking it to a shop to see if they know what’s up with it. I have tried rolling it, starting it in 1st. But end up in same situation.
     
  8. Oct 2, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Are your driveshafts installed? Haha, just kidding, wish you lived closer I’d like to try and help you out! Any way to open the inspection cover on the bell housing and see if your clutch plate is engaging or if there’s a gap with the clutch released? I know it’s hard to look in there but maybe a picture with your cellphone?
     
  9. Oct 2, 2020
    rejeep

    rejeep Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Rochester, NY
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    With motor running, can you depress the clutch pedal and shift into first or reverse without grinding?

    also

    If you start the motor with the tranny in gear do you get movement?
     
  10. Oct 2, 2020
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    It’s really frustrating when you work on it for several days I know. Sorry it’s not working for you. Wish I could help more.
     
  11. Oct 3, 2020
    shaun

    shaun Member

    Lebanon, Ohio
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    Oct 15, 2015
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    With the motor running i can only shift smoothly into 2 and 3rd. Grinds in 1st. This week I plan on trying to get it started in 1st. And likbluff63, I don’t have an inspection plate only the fork hole. I’d have to drop entire bellhouse and tranny
     
  12. Oct 3, 2020
    rejeep

    rejeep Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Rochester, NY
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    Assuming it’s a T90 1st gear is not synchronized.

    the syncro in 2 and 3 is absorbing some of the fact your clutch isn’t fully engaging. You are eating away at them.

    If you have maxed out your pushrod length you aren’t getting enough throw in your clutch arm. That’s the only external from bell-housing coefficient.

    only way to correct this is by an adjustable bearing or taller pivot stud.

    pull the tranny
     
    47v6 likes this.
  13. Oct 3, 2020
    shaun

    shaun Member

    Lebanon, Ohio
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    Oct 15, 2015
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    That was my thought. Thinking of pulling the Transmission and TC. Order adjustable pivot. I read that this fixed most of the problems. I should be able to see if I need an adjustable bearing without reinstalling it all by measurements. I read that some people had issues with the adjustable TO bearing and others didn’t. And yes the T90 does not have synchronized 1st and Reverse.
     
  14. Oct 3, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    A1FF8C2E-47E6-4958-BEA3-987751F9E165.jpeg On the front of the bell housing where it attaches to the motor you should have a dust cover/inspection plate where you can see the flywheel to inspect the teeth. Just some small screws holding it on. Not sure how it is on a 225 but may be enough room to see your clutch plate Or get your phone in there to take a picture?
     
    Last edited: Oct 3, 2020
  15. Oct 3, 2020
    shaun

    shaun Member

    Lebanon, Ohio
    Joined:
    Oct 15, 2015
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    390
    Oh that, yes I do have that and the teeth are fine, but no room to see anything else. Like maybe a 1/4” space between flywheel and bellhouse. I thought you were talking about on top of the bellhouse. I seen those before where they can access the clutch fork from..
     
  16. Oct 3, 2020
    zinertia2

    zinertia2 "and which part are you keeping?" 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Greencastle , IN
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    Possibly kind of silly but I bought a bore scope that works with my phone as the display (cheap). Had to use to thread a couple of bolts after I filly boxed my frame with only a dimple die hole every 12”. ( looks good, but they don’t line up in a couple of places where bolts need to go in frame).
    It is not great but can see stuff inside without taking everything apart.
    Dennis

    less than $30
    Inspection Camera Endoscope,Wireless Endoscope WiFi Inspection Camera 1200P HD Borescope Waterproof IP68 Snake Pipe Camera with 8 Led & 5M(16.4ft) Semi-Rigid Cable for iOS Android iPhone Windows Mac
     
    Last edited: Oct 3, 2020
  17. Oct 3, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Bummer, trying to think of something that would help!
     
  18. Oct 25, 2020
    shaun

    shaun Member

    Lebanon, Ohio
    Joined:
    Oct 15, 2015
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    390
    So I installed the adjustable pivot. I get about 3/8 of play still and no disengagement. As stated I can not get it to go into R or 1st but will go into 2nd and 3rd but will not move. My next thought is replace my MC with a 3/4 because I thought I had one in there but it measures. .70.
    Move the clevis down and to rear of pedal to try and get more throw in fork... I’m lost and running short on ideas.
     
  19. Oct 25, 2020
    shaun

    shaun Member

    Lebanon, Ohio
    Joined:
    Oct 15, 2015
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    So I dropped the Transmission installed the adjustable pivot ball. Still nothing and about 3/8 play before it hits the plate. It’s in neutral, TC is out of play. Won’t shift into R or 1st, but does in 2nd and 3rd with no movement. My next plan is to replace MC with a new 3/4 bore to match Novak slave. Thought I had 3/4 before but measured the inner rod and it measured .70. Dont know how much if a difference it will make. Also going to move the clevis connections on clutch pedal down and toward engine bay a little to get more throw. Running out of ideas. I have made sure TC is in neutral and high, as well as made sure it’s all bled. My ratio is currently 6:1 according to measurements (pedal length, pivot point to clutch rod) but only getting about 3/4 of actual MC engagement. I have about 4.5” of pedal movement before it’s floored. So that’s what im left with. Helping hands are welcome. Taking all your responses and trying them. I haven’t tried starting it in 1st yet. Don’t know what that will tell me.
     
  20. Oct 25, 2020
    Rich M.

    Rich M. Shoe salesman 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Maryland
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    Got a picture of your clutch fork / slave setup?
     
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