New Clutch Feels Wrong...

I am in the middle of my 79 CJ5 rebuild and have the tranny and motor bolted together and mounted to the frame. I installed a new heavy-duty off-road clutch. When I put my clutch pedal in and attached the linkage assembly, the pedal just didn't feel right. It felt very "springy" for the first half of pushing it in, then it would get REALLY stiff. If you held the pedal to the floor then let go of it, it would return to about 3/4 of the way out, then suddendly "pop" out the rest of the way. I have played with the adjustable arm that sits in that little indent and pushes against the throwout fork, but even at it's very farthest adjustment, the clutch pedal still pops. So I tried relocating the adjuster nut to rest against a much smaller little indent on the outer edge of the throwout fork. (From studying the repair manuals, I know this positioning is wrong). But this makes the clutch feel almost normal. Do I need a longer adjuster nut? Did I install something wrong? I would think that a brand new clutch would require less length on the adjuster nut than an old worn-out clutch. Please help! Thanks a lot!

 

I've heard that certain parts of the clutch linkage can be installed backwards and still look like it fits properly, causing odd clutch behavior. I'd recheck that. Then make sure your fork isnt contacting anything it shouldnt be and lined up properly with the throwout bearing.

 

Thanks for the suggestion. I am slightly afraid that something inside the bellhouse is off. How easy is it to install the throwout bearing and fork wrong? (My dad installed everything about a month ago before we started putting everything back together). If this is the problem, it would mean A LOT of work to get to it. We've already bolted the body down onto the frame and the driveline is all connected, etc. I tried looking at the linkage assembly for a long time and it looks like it can only bolt to the bellhouse and to the body one way. The brackets won't allow a backwards install. At least, I'm pretty sure that's the case. Could it be that the long screw/bolt that the adjuster nut threads onto snapped at one time (previous owner) or something? It feels like if I had just about 1/2 inch more length to thread out the nut, it would make a nice tight fit into the indent in the throwout fork.

 

You sure you got the throwout bearing on the right way? Easy to check; just shine a flashlight in the hole around the fork. Here is a pic of the correct throwout installation on my '76:

 

Did you add a body lift? I had to extend the push rod on mine.

I'm having difficulty getting my clutch fork out right. I have a 78 cj5. The pic of the throwout bearing jayhawk posted for you looks like mine. I remember when I put the fork in and heard the nice loud positive snap at engagement that it would probably be a pain to get out again. I have spent my entire weekend trying to get the fork out without breaking the clip on the throwout bearing or pulling the whole t-case, tranny and bellhousing in one piece.

 

Thanks everyone for your tips. My dad and I are going to tear into it tomorrow. After getting under there and pulling the boot off the bellhouse and looking inside with a flashlight, it looks to me like the throwout release fork is completely behind the throwout bearing plate rather than in the groove in the middle of the throwout bearing. In all the pictures I see, I can't really tell the exact way the fork is supposed to match up with the throwout bearing. Pictures make it look like the bearing has a square plate, then a groove for the fork to slip onto, then a round surface that pushes against the clutch. Is this right?

 

is your clutch disc directional? i know some discs that have a longer snout on one end of center of the disc and can only go in one way. also if its popping up, maybe the throw out bearing is hanging up on the shaft.....anyway, let us know what you find when you guys tear it back down

 

There's no groove if it's same as posted picture above. The clips on the bearing go around the end of the fork. There are 2 little nipples that on the end of the fork that plug into the bearing.

 

Im having some problems simalary to yours. I have all new parts in mine and its grinding when pushed in all the way and seems to not fully engauge normaly. I had a heavy duty clutch in mine for 8 years and changed it out because it broke everthing. Plate on fire wall, linkage at plate on fire wall, pivot ball on far end, clutch fork hole made where rod touches and finally the bell housing broke off. I would never install a heavy duty clutch again. I did not replace the clutch fork, I have got a new clutch fork and will pull motor or trans to replace it. This is the only peice of my clutch system that is not new. I hope it will correct my problem. It may be the same problem for you if the fork is bent or not able to correctly engauging the clutch. The clutch fork is only 12 dollars from 4wd hardware. I wish I had replaced it when I had it apart when I put the new clutch in.( I had pressure plate resurfaced, new pilot bearing , new clutch ,new thow out bearing, and all new clutch linkage)