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Project...Kahuna 66 cj6

Discussion in 'Builds and Fabricators Forum' started by bkd, May 11, 2007.

  1. Sep 15, 2010
    Mike S

    Mike S Sponsor Sponsor

    Cameron Park Ca.
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    Someone stole your clutch pedal:?:shock:
     
  2. Sep 15, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    sorry it was late when I posted........clutch pedal does not engage, need to determine why
     
  3. Sep 15, 2010
    '72CJ5

    '72CJ5 Member

    Modesto,...
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    May 12, 2010
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    could your fork have popped out? Unit looks good by the way.
     
  4. Sep 15, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    gotta drop the trans/tc again :(....................messed up the T/O bearing me thinks :evil:
     
  5. Sep 16, 2010
    Posimoto

    Posimoto Hopeless JEEP Addict Sponsor

    Minden, Nevada
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    Jim, if you are not using studs to align your tranny when you put it in you are doing it the hard way. Here's the drill. Get 2 or 3 bolts the same dia. as the tranny bolts, but in the 3 - 5" length. Cut the heads off and file a couple of flat spots on the cut end so you can get a open end wrench on them (5/16"?) Slip the tranny over them (perfectly aligned, by the way). Use the wrench to back the studs out and replace with the tranny bolts one at a time. As I recall, I had one bolt that needed to be quite a bit shorter than the rest. I use three. If you already knew this, well, now everyone else does too. ;)

    PS The same trick works great for t-cases too. You can just heave it up onto the studs and they hold it there so you can bolt it in. No jack needed.
     
    Last edited: Sep 16, 2010
  6. Sep 16, 2010
    willys59cj5

    willys59cj5 Sponsor Sponsor

    Gilroy, CA
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    That is awesome advice John. Next time I have to drop mine I'll remember that one.
     
  7. Sep 16, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    :oops: nope hadn't thought of that, i'll give it a try...thanks
    looks like the T/O bearing is NOT there....thinking it musta fell off the fork and I'm not sure what I was feeling/looking at when I was installing the trans :(:(:(
    shift fork got into clutch fingers..... hoping it hasn't been damaged to the point of needing replacement, gonna spend the day tomorrow trying to rectify the situation
    Jim
     
  8. Sep 16, 2010
    EricM

    EricM Active Member

    Southern California
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    Dec 19, 2007
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    I think I used a hacksaw to cut a notch in the end of the aligning bolts, I used a screwdriver to back them out.
     
  9. Sep 16, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    Ok where's the icon showing the guy beating his head into a wall :rofl: mehh


    found the problem....dropped the assembly and it was obvious from the get go. The throw out bearing was on backwards...(yea I know I'm looking for a dunce cap to wear)...it was one of the new style T/O that slide over the input but don't clip to the fork. My only excuse is I was tired and in a hurry...live and learn
    Damage report...throw out bearing , shot.....fork bent but repairable......clutch fingers bent and twisted, toast
    Good news is I have another clutch and throw out bearing that I'm pretty sure will work. I'm going to try to get it together today...pics to follow
    Jim
     
  10. Sep 16, 2010
    '72CJ5

    '72CJ5 Member

    Modesto,...
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    I know this is probably a dumb question for you more seasoned fellers, but you cant just bend the fingers back to where they need to go? Or are they beyond the "it'll buff out" phrase?
     
  11. Sep 16, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    I thought about but you can see the damage to the "fingers" is pretty excessive
    [​IMG]
    I'll just use the other pressure plate I have and reuse the disc as it looks fine
    Here's the t/o bearing......you can see it ate the plastic collar pretty good, I'll use the older style t/o on the left
    [​IMG]
    had to pull up the insulation, molded rubber mat, and the carpet to get to everything
    [​IMG]
    I was able to straighten out the shift fork so hopefully I'll get this back together by tonight
    Jim
     
  12. Sep 16, 2010
    jpflat2a

    jpflat2a what's that noise?

    Riverside CA
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  13. Sep 17, 2010
    Posimoto

    Posimoto Hopeless JEEP Addict Sponsor

    Minden, Nevada
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    I feel your pain, Jim. How about this one? :dead horse:
     
  14. Sep 17, 2010
    HeavyIron

    HeavyIron Member

    Orange, CA
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    Sucks, sorry man
     
  15. Sep 17, 2010
    jeep67

    jeep67 Member

    Shasta, Ca
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    Dec 11, 2006
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    Bummer, Jim. I hope it goes back together for ya without issue.
     
  16. Sep 17, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    thanks guys......got the other pressure plate mounted and used the other throw out bearing. I got the trans mounted and had to remove 1/2" from my hydraulic clutch push rod to get adjustment right.
    I haven't run it yet as I need to put in the tub panels/tc-od shifters/insulation-carpet etc......but it does feel right clutch pedal wise and shifts through the gears nicely
    Hope to finish Sat. + Sun. eves
    Jim
     
  17. Sep 17, 2010
    Mike S

    Mike S Sponsor Sponsor

    Cameron Park Ca.
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    That is great news:)
     
  18. Sep 21, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    Kahuna is finally back in operation and back together !!!.........
    [​IMG]
    took it out yesterday and the clutch slipped badly, crawled under and could see through the access hole that I'd forgotten to tighten the pressure plate completely:oops::oops: , tightened it this evening and it drives and shifts nicely :)............been a long time w/o the Jeep, looking forward to taking it out on a cruise
    This won't come as news to you veterans but.......I've learned through this debacle that working with a negative attitude or overly tired results in bad juju on the project. This has been one of the most difficult projects I've tackled on the 6 and much of it was self inflicted....GLAD IT'S DONE!!!!!!!!!
    JIm
     
  19. Sep 21, 2010
    krkx93

    krkx93 Member

    louisiana
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    May 16, 2010
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    81
    question. how do you keep your windsheild from flopping around and the latches come undone.
    it seems like nomatter how i adjust the latches they always come undone and the windsheild falls down..
    great looking 6 btw. i love that color
     
  20. Sep 21, 2010
    bkd

    bkd Moderator Supreme Staff Member Sponsor

    K-Town Tenn.
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    my latches are pretty snug and really haven't come loose.........I usually have a bikini top or full top in place as well which keeps tension on the windshield.................have done lots of runs w/o a top and never had them come loose, have you adjusted all you can???
    Jim
     

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