Clutch Clutch fork hitting bellhousing, clutch not disengaging.

[AndyD in BC]

My CJ5 clutch fork is hitting the bellhousing when the clutch is depressed. The pedal just gets stiffer, and the clutch won't disengage properly. It seems the fork is not pushing the throwout bearing quite far enough forward, then the fork hits the bellhousing and I get no more travel.

My first instinct was that the pivot ball was missing, but it was not. All springs are in place, the linkage was adjusted properly to the fork. Does anyone have an idea whats going on? I'm wondering if I have the wrong fork or bellhousing.

So far troubleshooting has been:

1. The pivot ball is in place
2. All springs are in place
3. The clutch plate is not installed backwards
4. The clutch linkage is adjusted properly

Here are some details:

• 76 CJ5
• AMC 258 i6 / 4.2l
• T-18

The engine was replaced about 15 years ago, it hasn't been on the road since, so I'm wondering I the guy who did the engine mismatched some parts. I'm really at a loss.
I'm planning on a new throwout bearing, but am holding off on wondering to see if I can figure this out to make sure I get the right parts.


This is the fork I have w/ throwout bearing.


It has the top ground out as needed for a T-18 swap, but I don't have the bellhousing bolt positioning that would require the mod. My T-18 is factory. However, if this notch were not there, I think it would also hit the bell housing.


You can see in the corner of the old boot where the bottom of the fork has been wearing against the bellhousing.

• I have some thoughts to fix the problem with workarounds, but they don't diagnose the problem.
• Grind out the other side of the fork, but I am afraid of weakening the fork too much
• 3d print or mill a pivot ball spacer to move the fork forward 1/4" or so.

Anyone got any ideas or advice? Thanks!

 

[KRUPP]

Interesting. I’m working on replacing Transmission now on my ‘86 7. Replacing the clutch as well while it’s apart.
In my recent purchases, I looked over different options. There is an adjustable Throwout Bearing available for those adapting various combos of engine to Transmission . It screws in or out to achieve the proper air gap between the bearing and the diaphragm fingers. This gap should be about 1/8”.

 

[Belizean]

I’m not a big Transmission guy, but when I did my swap from AMC 150 /T-4 swap to AMC 258 i6 / 4.2l /T177 I was looking at that same adjustable T O bearing. I got one if you want it to try. You can have it if you want. I didn’t use or even try it. I used the one in the box with the Luk kit. I don’t remember it being that cost at all.

 

[AndyD in BC]

I’m not a big transmission guy, but when I did my swap from amc 150/T4 swap to 258/T177 I was looking at that same adjustable T O bearing. I got one if you want it to try. You can have it if you want. I didn’t use or even try it. I used the one in the box with the Luk kit. I don’t remember it being that cost at all.

That would be awesome, It's been tough to find info to figure out what the best fix is. If it doesn't work out, I'll pass it along to someone else. I'll send you a PM.

 

[Belizean]

Wow my mistake on this AndyD in BC. I thought this was KRUPP’s thread. I guess I should have looked a lot better. I knew he was working on his Transmission and I offered it to him to try since he and I have been here on the forum for a while. I will see if he wants to try it. If he does not I will let you know and have it at a lower cost for sure than what Novak wants.

 

[AndyD in BC]

Wow my mistake on this AndyD in BC. I thought this was KRUPP’s thread. I guess I should have looked a lot better. I knew he was working on his transmission and I offered it to him to try since he and I have been here on the forum for a while. I will see if he wants to try it. If he does not I will let you know and have it at a lower cost for sure than what Novak wants.

Totally fair, let me know

 

[Belizean]

I sent you a PM.

 

[KRUPP]

Wow my mistake on this AndyD in BC. I thought this was KRUPP’s thread. I guess I should have looked a lot better. I knew he was working on his transmission and I offered it to him to try since he and I have been here on the forum for a while. I will see if he wants to try it. If he does not I will let you know and have it at a lower cost for sure than what Novak wants.

I don't need that Throwout Bearing. It was just a suggestion as a fix for Andy D. Thanks for thinking of me though.