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Clutch Won't Disengage

Discussion in 'Early CJ5 and CJ6 Tech' started by Monza, May 20, 2022.

  1. May 20, 2022
    Monza

    Monza New Member

    Canaderp
    Joined:
    Jun 26, 2019
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    The rebuild is very recent, so far the odometer only has 150Kms on. On my last outing the I noticed I was having trouble shifting in and out of gears and when fully stopped , I couldn't engage 1st with the clutch fully depressed. I initially thought perhaps cables had stretched and that it would only need an adjustment. No such luck. I believe the clutch is adjusted correctly.

    I just finished removing the body around the inspection cover and I've found something odd. I'm not sure if its the cause of the problem or a symptom. I was hoping to consult the hive mind on next steps.

    The details:

    1960 CJ5
    F134
    T90
    heavy duty clutch (9.25)

    For some reason one of the fingers of the clutch is 'stuck' way out place. My thought would be if its stuck like that the clutch should be having trouble engaging, but I've never seen this before.

    Resizer_16530717527010.jpg

    The finger on the right is the one 'stuck'
    I haven't tried anything yet, my gut reaction is grab the vicegrips and relocate the finger by brute force.

    I can't find the paper work for the order for the clutch parts, but its likely to be a Crown or Omix part.
     
  2. May 20, 2022
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    I think you already know that pulling the transmission is your only option. If you got it unstuck it'll more than likely do the same thing again. I wouldn't want to trust it if it was mine.
     
  3. May 20, 2022
    Walt Couch

    Walt Couch sidehill Cordele, Ga. 2022 Sponsor 2021 Sponsor 2020 Sponsor

    cordele, Ga.
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    It's broke for sure. Needs to go back to the re-builder. Nothing here you have done to cause this. When you go back together be sure to put that short return spring on the throw-out bearing.
     
    timgr and Ol Fogie like this.
  4. May 20, 2022
    Monza

    Monza New Member

    Canaderp
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    Jun 26, 2019
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    I suspect you're correct, there is major surgery in my future.

    I've been able to find on RockAuto some aftermarket clutch options, but they have all been for the 8.5 clutch. Is there any aftermarket options for the 9.25 clutch?
     
  5. May 20, 2022
    Twin2

    Twin2 not him 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Virginia Beach, VA
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    just throwing this out there
    are all the bolts holding pressure plate tight
     
  6. May 20, 2022
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Hills of NH
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    On occasion rodents will leave debris that can jam a clutch.
     
    sterlclan likes this.
  7. May 22, 2022
    sterlclan

    sterlclan Member 2022 Sponsor 2021 Sponsor

    exploring the...
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    his looks way too clean for that though
     
  8. May 22, 2022
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    To me it looks like something broke.
     
  9. May 23, 2022
    Monza

    Monza New Member

    Canaderp
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    Jun 26, 2019
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    I've noodled on this for a couple of days.

    The clutch is stupid simple, the arm pivots on the cover and pulls up (against the spring pressure) the pressure plate. The borked arm is 'free' to move. I can pull it back into the fully closed position, but it falls back into its current position. The only way that's possible is that the surface of the pressure plate can't fully rest against the surface of the clutch disk. So the correct answer appears to be debris is stuck in there.

    I'm going to try and add shims between the throwout bearing and the fingers, so I can open the pressure plate to its absolute maximum. (I'm hoping at this point what ever is trapped falls out) I will likely use a wire to try and fish around in the gap and knock whatever it trapped out.

    I'm thinking it has to be pretty thin to have gotten stuck in the first place, I'm wondering if a small washer found its way in there. Hoping the the item(s) are metal and I can fish them out with a magnetic pickup tool. There will likely have been some damage to the clutch surface, but I travelled about 10 kms home with the clutch not working, so hopefully the damage isn't immediately terminal and I can send it.

    I'll follow up if the procedure is a success, if not I guess the motor is coming back out.
     
  10. May 24, 2022
    Monza

    Monza New Member

    Canaderp
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    Jun 26, 2019
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    I've failed at clearing the debris, if it was debris stuck between the pressure plate and clutch disc.

    I've ordered a LUK clutch kit from rockauto and it should be landing shortly, I'm still hoping the 9.25 clutch can be rescued, but I'm prepared to use the 8.5 LUK if needed.

    As I've already got the sheet metal around the transmission removed, I'm thinking the path of least resistance will be to drop the transmission out the bottom and leave the motor in place. I'm not looking forward to aligning a clutch laying on my back under the jeep.

    Any tips on the bottom out procedure?
     
  11. May 24, 2022
    Jw60

    Jw60 WRPD855 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Sedalia MO.
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    Pull the transfercase shifters off and take the shift tower off the transmission. Make a cover for the transmission. You might find an alignment tool for the clutch.

    That would be a good 3d printer job for my boys...
     
  12. May 24, 2022
    52M38-73CJ5

    52M38-73CJ5 Member

    Renton WA
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    On my 73CJ with the 3 finger clutch one if the bolts holding the pressure plate in place backed off causing it not to fully disengage. You could possibly have the same issue. Mine happened slowly needed adjustment over time till I was no longer able to disengage. I installed this clutch in 2020 then having to do it again just over a year later was very frustrating.
    I Resurfaced the flywheel and replaced the pressure plate. This time I tack welded the threads to make sure nothing like this could happen again. They mess up the threads on the bolts to keep the nuts in place. Apparently sometimes not well enough. Mess up the threads more or weld them on like I did.


    clutch1.JPG clutch2.JPG clutch3.JPG
     
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  13. May 25, 2022
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Medford Mass USA
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    Where did you source the 9.25" clutch cover? Curious.
     
  14. May 25, 2022
    47v6

    47v6 junk wrecker! 2022 Sponsor 2021 Sponsor 2020 Sponsor

    USA
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    One second search for a clutch alignment tool
    https://www.kaiserwillys.com/willys...MIoru2tu769wIVDBXUAR3sYwzJEAQYAiABEgKqZ_D_BwE
     
  15. May 25, 2022
    Monza

    Monza New Member

    Canaderp
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    My general rule of thumb was to buy brand name aftermarket parts if available, if not, crown then finally omix.

    It looks like I followed that logic, I ordered the Pressure Plate (Clutch Cover) from Summit (they ship free to Canada) and it appears they only carry Crown parts.
     
  16. May 25, 2022
    Monza

    Monza New Member

    Canaderp
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    My back thanks you, my knuckles thank you, my Jeep thanks you.

    Those were my symptoms and that was my issue. I tightened up the bolt and as I did so, the finger climbed back into position. I stopped when it looked visually to be in place. Sure enough the transmission now disengages.

    Before I close it up, I'm planning on spinning the motor round by hand and ensuring each of the fingers are approximately equal distance from the throw out bearing and mashing the threads up with a punch. I'm not brave enough to try and weld through the inspection hole.
     
  17. May 25, 2022
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Hills of NH
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    (y)
    Another win for ECJ5!

    :beer:
     
  18. May 25, 2022
    Oldpappy

    Oldpappy A.C. Fults - Curmudgeon at large 2022 Sponsor 2021 Sponsor

    East Tennessee
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    If you aren't brave enough to weld you could possibly get a long punch aligned where the bolt meets the nut, give it a good blow with a hammer to stake the nut to the bolt. Then rotate it around and do the same to the other two.
     
  19. May 25, 2022
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    Wow! Tha's a new one to me. Seems like if something can happen, no matter what it is, someone here has experienced it. o_O :beer:(y)
     
  20. May 25, 2022
    52M38-73CJ5

    52M38-73CJ5 Member

    Renton WA
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    Well after AMC took over there were no more inspection plates. I had a fun weekend.
    Monza Glad my post was helpful
     
    Ol Fogie and Glenn like this.
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