Stubborn cj5

[highroad]

I have replaced the clutch. If I put Transmission in gear, Transfer Case will not go into 2hi or anything else. It will only grind. If I put Transfer Case in 2hi, the Transmission will not go in gear. I have the clutch adjusted as far as it will go. The TO bearing arm is hitting the bell housing. ???? T-176 Dana 300

 

[Torxhead]

From your description, it could be that the throwout lever pivot ball has fallen out. It is supposed to be held in with a spring. Anyway, i'm thinking it must be torn down again, tough break.

 

[Hedgehog]

Probably needs a tear down ..... interesting problem in that it won't allow the two units to interact. How are your linkages? Probably fine .... you worked on your clutch, it's a problem with the clutch.

 

[caveman]

It could be a warped clutch plate. Very rare now days. The last one i encountered was 40 years ago.

 

[tarry99]

I have replaced the clutch. If I put Transmission in gear, Transfer Case will not go into 2hi or anything else. It will only grind. If I put Transfer Case in 2hi, the Transmission will not go in gear. I have the clutch adjusted as far as it will go. The TO bearing arm is hitting the bell housing. ???? T-176 Dana 300

You replaced the clutch.........did you replace the throw out bearing?
If so was the replacement bearing length the same from the clutch fork groove to the face of the bearing?
Is the clutch fork correctly installed in the groove in the bearing and not in front of the groove?
Expand on why the clutch fork ( bearing arm as you call it) is hitting the bell Housing? And Where? in the rear of the fork opening on the side or inside near the motor?
Is the clutch fork located correctly in the pivot ball?

 

[Lumpy Grits]

How much pedal free-play do you have?
You want 1-1 1/4" at most.
What all did you replace? Clutch friction disc-pressure plate, pilot bearing, throw-out bearing??????
How badly worn is the clutch linkage?
" I have the clutch adjusted as far as it will go" What do you mean buy this?
LG

 

[Thorwon]

I have replaced the clutch. If I put Transmission in gear, Transfer Case will not go into 2hi or anything else. It will only grind. If I put Transfer Case in 2hi, the Transmission will not go in gear. I have the clutch adjusted as far as it will go. The TO bearing arm is hitting the bell housing. ???? T-176 Dana 300

The first question I have for you is did you install the clutch with the spring side towards the Transmission ? If not then it's not disengaging because the springs are in contact with the flywheel bolts.
If this is the case then you will have to take it all back apart.

 

[Hedgehog]

We can debate your problem all day long, but in the end you have no choice but to pull the Transmission back and install the clutch properly, without question, there in lies your problem.