Hydraulic Clutch Problem

OK, I might have 2 different problems with the clutch.
Let me start with I did a hydraulic clutch conversion from Novak about 5 years ago when i installed the SM420, and it worked perfectly. I have torn down entire Jeep and have been re-building for last 4 years. I finally can see lite at end of tunnel with this build. I finally got all the wiring done, motor started and checked all lines for leaks and bleed brakes. everything worked except the clutch system.
First problem is the slave cylinder will push out but wont return to normal position, unless I crawl under jeep and push it back by hand. When I do this it forces all the fluid back into the master cylinder and it over flows. I have bleed the system several times and nothing changes. Do you think slave cylinder/master cylinder is bad?
Second problem is after I removed the slave cylinder, I could push the clutch arm back and forth by hand with no resistance. I don't think I should be able to do this?
Thanks for your help.
Rob

 

I'm no hydraulics expert, by any means but, it seems to me that if the proper amount of fluid is in the system, there is no reason that the m/c should overflow when you push the pedal back. This is how it would normally operate so, operating it "manually" should not affect the fluid level. Unless you are exceeding the designed stroke of the slave cylinder, if that's possible. In other words, pushing it back too far and pushing the fluid out. Or the slave is sucking air when you operate it but, that doesn't seem to be the case.

I believe the slave requires spring pressure from the clutch mechanism, specifically the 3 finger or diaphragm part, to help it return to it's "normal position." If you are feeling no resistance there, when you manipulate the clutch fork by hand, then I'd say something is amiss in there. Not sure if return springs would help any of this but, I think your problem lies deeper than that. Is the throw out bearing properly installed?

There are a few really knowledgable folks here who can be more helpful than I but, maybe this will get you started.

 

The Novak slave has a longer than normal stroke.........near 2 inches total if I remember correctly...........although most clutch master cylinders do not have that much travel.........so it sounds as if your returning more volume back to the master than it can hold...........I know that sounds incorrect but as a closed system once installed and bleed from from the master cylinder side the volume pushed by the stroke in the master is all the system knows.

As far as the clutch.................5 years of setting there I would guess the disc is rusted to the pressure plate or flywheel or both and the pressure plate is just not releasing............hence you have excessive free play now........Probably need to pull the tranny and free everything up.

 

Sounds to me like there might be an issue with the pivot on the clutch fork too...

Sent from my SCH-I500 using Tapatalk 2

 

Thanks for the info. It sounds like I'm gonna have to drop tranny. ....two steps forward......one back!!!!!!!
Ill keep you informed on what I find.