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Old 12-15-2013, 01:24 PM   #1
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Clutch Pedal let go?

Hey guys, friend of mine has a 99 jeep tj 4.0, anyways i just had to go pull him out of the woods, his clutch pedal let go, and i was hoping for some insight on how we could fix this ? Basically me not being knowledged about it, from my point of view it looks like the clutch pedal is connected to a plunger type of device. anywho the plunger thing is dangling, and the clutch is not working at all. You can push the clutch in and there is no resistance at all. We managed to start it by pushing in the rod thing ( i think it is a sensor ), any one have a write up or know what this problem is ??

Looks like a plastic clip broke as well.

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Old 12-15-2013, 02:01 PM   #2
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Got a pic? The clutch pedal pushes the piston inside the master cylinder that forces fluid into the slave cylinder, pushing the clutch away from the flywheel.

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Old 12-15-2013, 02:05 PM   #3
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Where is the part dangling from. Is it under the dash near the the clutch pedal, or is it the clutch hydraulic system's slave cylinder that bolts to the side of the transmission on the driver's side?
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Old 12-15-2013, 02:10 PM   #4
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part is dangling from under the dash, i will go take a picture of it now in a minute and upload it
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Old 12-15-2013, 02:23 PM   #5
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My clutch pedal went to the floor a few years back,

On mine the spring that holds the throw out bearing to the fork broke allowing the throw out bearing to rotate 90 degrees and slide inside the fork.
This allowed way too much clearance, thus allowing the clutch pedal to have free full travel. The only fix for my problem was to drop the transmission and replace the throw out bearing and.... 'Since You Are There'..... might as well replace the clutch.
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Old 12-15-2013, 02:27 PM   #6
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Did you notice his last post saying the dangling part is located under the dash?
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Old 12-15-2013, 02:30 PM   #7
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yep, I got several parts dangling, I just thought it was a 'Jeep Thing'.....lol
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Old 12-15-2013, 03:32 PM   #8
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Here are the pics :
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Old 12-15-2013, 07:48 PM   #9
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the straight end of that rod goes into the clutch master cylinder that is sticking through the firewall, and the round end goes over a pin on the clutch pedal but there is a plastic bushing that goes between them (the pin and the hole in the rod). The Chrysler part No. for the bushing is 4643448 and it looks like this....
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Old 12-15-2013, 07:48 PM   #10
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Okay, I appreciate it Thanks!! It looks like a simple fix, Funny how something so small can make your jeep not driveable
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Old 12-16-2013, 04:16 AM   #11
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Just as an FYI, you can use a zip tie to temporarily attach the actuating rod to the clutch pedal. Just slip the hole in the rod onto the pin on the clutch pedal and wrap a zip tie around to hold them together. That little plastic bushing is prone to break at just the wrong time
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Old 12-16-2013, 08:31 AM   #12
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Quote:
Originally Posted by giles45shop View Post
Just as an FYI, you can use a zip tie to temporarily attach the actuating rod to the clutch pedal. Just slip the hole in the rod onto the pin on the clutch pedal and wrap a zip tie around to hold them together. That little plastic bushing is prone to break at just the wrong time

+1 on the zip-tie idea. I actually put two on mine as a fail-safe. That little plastic bushing, whether a Mopar or Pep-Boys item, breaks very easily and is poorly designed. One or two zip ties---not tightened too much but left somewhat loose so as to provide enough play in the peddle but also keep the pedal attached in case of crappy plastic bushing failure--is all you wil ever need.
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Old 12-16-2013, 08:46 AM   #13
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If you're interested here's a write up that someone did about replacing the plastic bushing with a piece of tubing and an e-clip. I was going to do it, but I found that the original plastic bushing was a whole lot easier to install and my original one lasted 130,000 miles (and they're cheap) so when I bought a new one, I bought two and just keep an extra in my parts supply. The link is mis-labled but works.
TJ Fender Flare Installation
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Old 12-16-2013, 09:00 AM   #14
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The rod to pedal connection is an easy fix but I'm more concerned why/how it came off the firewall where it attaches to the master cylinder.
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Old 12-16-2013, 09:08 AM   #15
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Thanks for the link! I hear you, It was in the garage recently and had a whole new clutch put in, fly wheel , etc. I am thinking it wasn't properly put back together or it was a freak break?
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Old 12-16-2013, 09:12 AM   #16
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The clutch pedal mechanism is not touched during a clutch installation, I doubt they ever got near that part that fell off.
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Old 12-16-2013, 09:14 AM   #17
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The rod to pedal connection is an easy fix
Unless you're an old overweight guy like me that can't get into contortionist positions anymore. ...It's pretty bad, when I would rather change a clutch than do anything under the dash..!
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Old 12-16-2013, 09:17 AM   #18
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Ha yeah I hear you on the physical problem of working on anything under the dash, it's a back breaker. I've been under there three times to do significant work & I dreaded it each time.
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Old 12-16-2013, 09:19 AM   #19
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How does it go in through the firewall? I can't find any pictures, the pedal part makes sense however i can't picture how it goes through the firewall
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Old 12-16-2013, 10:03 AM   #20
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Its front is what attaches to and pushes on the clutch master cylinder, located next to the larger brake master cylinder mounted on the power brake booster on the firewall.
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Old 12-16-2013, 11:08 AM   #21
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Quote:
Originally Posted by Water Dog View Post

Unless you're an old overweight guy like me that can't get into contortionist positions anymore. ...It's pretty bad, when I would rather change a clutch than do anything under the dash..!
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Originally Posted by Jerry Bransford View Post
Ha yeah I hear you on the physical problem of working on anything under the dash, it's a back breaker. I've been under there three times to do significant work & I dreaded it each time.
I gave up on that 'twist the back, pinch the shoulders, contort the arm' maneuver. Now I take an extra 10min and remove the seat. Throw a blanket down and I have dozed off while lost in thought lol.
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Old 12-16-2013, 01:05 PM   #22
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All Zip tied up for now , problem quickly fixed !! You guys are too awesome!

Thanks
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Old 12-16-2013, 01:45 PM   #23
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I gave up on that 'twist the back, pinch the shoulders, contort the arm' maneuver. Now I take an extra 10min and remove the seat. Throw a blanket down and I have dozed off while lost in thought lol.
I did the same...twice. The problem wasn't getting there, it was getting back out...

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