Clutch... am i spending time under the jeep this weekend?

[Keith]

On the way home from work yesterday, my clutch suddenly started giving me problems. Here goes... lets see if i can remember the finer details:

-- About 2/3rds of the way down, it changes from smooth to really rough travel... feels like I'm pushing it through gravel
-- All the way pressed in, it feels / sounds like something is rattling / vibrating
-- Pop in first, and there is a squeal / vibration - which does go away once i've fully taken my foot off the clutch
-- Trying to pop in to 2nd - feels like im really trying to rip the shifter out of first, and then it's hard to get it in to second.
-- Third, fourth, fifth gear are more or less ok

Looked under the jeep, and there doesn't appear to be any leaks / loose parts.

Drop the skidplate, tranny, and fully replace of pressure plate, clutch disk, pilot bearing, throwout bearing?

03TJ, 80k miles... daily driver, but definitely used off-road.

Found this write-up... wondering if there is anything more specific anyone here knows of?

http://www.4x4xplor.com/clutch.html

Thanks!
K

[ZAEDOCK]

Secure chain over the top of the transmission/t-case assembly and TIGHTEN . DANGER: FAILURE TO DO THIS STEP WILL RESULT IN SERIOUS INJURY WHEN THE TRANS IS DISCONNECTED FROM THE REAR OF THE ENGINE AND FALLS OVER ON YOU.


Wimp.



Disconnect driveshafts / tranny shifter /wiring
Place a piece of 2x4 behind the head of the engine
Place jack under tranny
Remove belly pan
Pull T-Case
Lower tranny/engine until engine head rests against 2x4 at the cowl of the body
Disconnect hydro line
Remove tranny
Replace clutch components / resurface flywheel

Reinstall in reverse order.

[Keith]

so..... you're saying that I need to repace the clutch, huh? EXCITING!

[ZAEDOCK]

It sounds like the throwout bearing or a broken spring in the disk or pressure plate.

[Keith]

I tried staying very calm last night... that &%$@!*$ TC linkage may be the most ridiculous setup that is under the jeep. I cannot get the bracket loose from the tub. I'm going to cut the bolts tonight. While I'm at it, im going to fully replace the linkage. Anyone have any reccomendations?

found this guy... seems like it fits the bill!

http://www.quadratec.com/products/52554_210.htm

[johnsxj]

That might work. Or you could go with a Novak shifter.

[Keith]

this one looks pretty slick... cable.

http://www.novak-adapt.com/catalog/shifters/sk2xc.htm

maintains the stock handle, removes all the original components. Seems to have gotten positive reviews... ordered! I cannot wait to get rid of the stock mechanism.

[nostaw]

this one looks pretty slick... cable.

http://www.novak-adapt.com/catalog/shifters/sk2xc.htm

maintains the stock handle, removes all the original components. Seems to have gotten positive reviews... ordered! I cannot wait to get rid of the stock mechanism.

If you can, please report back on how you like that one... The linkage in my XJ has.... issues...

It isn't a priority right now though.

JW

[Keith]

ill let you know how it turns out.

in other news... blown retainer shaft! clutch needs replacing too... but DAMN. Glad I stopped driving around immediately.

[Keith]

Tranny is BOLTED BACK ON! Still need to install the Novak shifter, get the skids on, and triple check stuff, but the majority is done. That was a LOT of fun - I'm pretty impressed with myself.

Started up the jeep to feel the clutch... better than when I bought it. So smooth. I'll post up pics of the destroyed parts later... all in breakage: teeth on the pressure plate, throwout bearing, retainer shaft.

AND I managed to keep the garage a helluva lot cleaner than Ryan!

[Keith]

If you can, please report back on how you like that one... The linkage in my XJ has.... issues...

Installed in 30 minutes, no need to adjust, shifts a helluvalot better than the stock TJ linkage! Big fan so far.

[nostaw]

If you can, please report back on how you like that one... The linkage in my XJ has.... issues...

Installed in 30 minutes, no need to adjust, shifts a helluvalot better than the stock TJ linkage! Big fan so far.

Thanks... Good to know.

I've tweak'd the unit-body of the XJ and the linkage is finicky, but it works "good enough" for now. If it gets much worse I'll have to do something about it though.

JW