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Old 07-06-2014, 07:01 PM   #1
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Clutch problems

I have a 99 sport with the AX 15, 5 speed manual transmission. Was running to town today and was shifting gears when clutch pedal half way down was really firm. Couldn't get into gear. Pulled over and pedal is really hard about half way down. Had to start jeep in 2nd gear and limp my way home. Reservoir is full. Only thing I can think of is master cylinder ate its pigs. Any other thoughts?

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Old 07-06-2014, 07:02 PM   #2
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Could be hydraulic but it sounds more mechanical, like a bad throwout bearing or its linkage.

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Old 07-06-2014, 07:22 PM   #3
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How do I diagnos?
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Old 07-06-2014, 10:01 PM   #4
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Someone must of had this happen. Am I fighting a slave or master cylinder or something with the throw out bearing?
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Old 07-06-2014, 10:24 PM   #5
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I suggest you start by pulling your slave cylinder out and use a large screw driver or piece of dowel rod to try and manually disengage the clutch. It should take some pretty good pressure, but you should be able to do it. If you can't or if it feels like it's catching or binding, or has noises of broken parts, it's likely your throw out bearing or pressure plate....Clutch job. If it works smoothly take a closer look at the slave/master cylinder. When you pull the slave out, take some measurements. The pictures below are typical of what they should be on a 1999 4.0 with the AX15.
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Old 07-06-2014, 10:29 PM   #6
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Pull the slave out and see if you can actuate the clutch with a long screwdriver. That'll tell you if everything is kosher in the bell housing. Then i guess you could carefully work the pedal while someone holds the slave pin against the floor/frame, but be careful not to over extend it. I'm not sure how well they seal/retain without a clutch fork to stop the plunger from blowing out.
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Old 07-06-2014, 10:29 PM   #7
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Ok, thanks. When I take slave cylinder loose from housing can I slowly push on pedal to see if I loose my hard pedal? Just can't think it's internal, just had transmission rebuild with new clutch a year ago.
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Old 07-06-2014, 10:32 PM   #8
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Should fluid level go down when I push in clutch pedal? Like I said goes half way down normal, then gets really hard.
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Old 07-07-2014, 09:59 AM   #9
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Originally Posted by ljjp10 View Post
Ok, thanks. When I take slave cylinder loose from housing can I slowly push on pedal to see if I loose my hard pedal? Just can't think it's internal, just had transmission rebuild with new clutch a year ago.
With zero resistance on the slave from the pressure plate, there wouldn't be any resistance in the pedal. You would have to be very careful not to blow the slave apart.

There is nothing special about Jeep clutch hydraulics. There is no force multiplication in the hydraulics like there is in a brake system. It is simply a hydraulic linkage where you push fluid at one end to move the rod at the other end. The force multiplication comes from the clutch pedal lever (arm) and your foot. Both master and slave are approximately the same size.

Depends on what parts were used to do the clutch. Some clutch kits come with a throw out bearing carrier with plastic ears (autozone etal) that have a habit of breaking off. You can do a search on clutches on here and find many that have had to replace bad new clutch parts. If you find yourself having to replace the clutch, get a LUK clutch kit. They are available from Parts Geek for <$100.
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Old 07-07-2014, 10:40 AM   #10
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Quote:
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Should fluid level go down when I push in clutch pedal? Like I said goes half way down normal, then gets really hard.
This is with the slave removed? I believe some fluid will go down but not a lot. If its hard when you push down with the slave removed (and the piston on it is secured from flying out) then I would recommend checking your clutch pedal linkage to make sure nothings getting caught (i.e. a rubber floor mat that has crawled too high or something). If that's not the case then it would seem like something is not right with your master cylinder. Hard pedal doesn't typically indicate air in the lines, but it doesn't hurt to bleed your slave while its out by pushing on the plunger about 20-30 times slowly. Make sure the fluid reservoir never gets low or it will suck in more air. Good luck.
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Old 07-07-2014, 01:08 PM   #11
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OK. Will work on tonight after work. The clutch I installed a year ago was a Luk. Thanks again
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Old 07-07-2014, 06:31 PM   #12
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Now I'm confused. Took off slave cylinder and tested seemed to work OK, but wouldn't push out very far and still had a hard pedal half way down. Messed with the clutch release arm, didn't have much side to side play, but was able to pull it back toward me, is the normal? Pushing on it seemed like I could push in a little, but not much, remember clutch is only a year old, with easy driving. Before I put back together I pushed plunger in and out 6 or 7 times and got it to come out farther. Bolted back up and pedal was good. Started up, backed out of shed and started driving down the road, shifted half dozen times and was working great, then went back to hard pedal and couldn't shift. Hoping this proves it in the master and slave component. What are your thoughts. Thanks Again
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Old 07-07-2014, 07:24 PM   #13
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Check your upper pedal where the master cylinder is attached to the pedal. There is a plastic bushing there that may be torn up.

If that is not it, it is most likely an issue in the master or slave. the whole hydraulic system is available as a package all put together and pre-filled, and pre-bled.
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Old 07-07-2014, 08:08 PM   #14
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ID:	1278809Not sure where that should be. This is what mine looks like. Hope I did this right. Can I buy just the slave or do I have to buy the whole set up?
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Old 07-07-2014, 08:33 PM   #15
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The ring on the end of the master cylinder rod is supposed to ride on the pin on the clutch pedal with a plastic bushing in between. It's hard to tell on your picture, but it looks to me like the busching is broken and has slid up the rod. That rod might not even be connected to the clutch pedal arm, but just being pushed on by the pin.
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Old 07-07-2014, 09:12 PM   #16
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Water Dog I think I got a better picture. Believe it is there. I think I'm going to replace slave cylinder. Is it possible to just replace it or do I buy assembly as a whole with master and slave? Thanks for all your help
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Old 07-07-2014, 09:21 PM   #17
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Water Dog I think I got a better picture. Believe it is there. I think I'm going to replace slave cylinder. Is it possible to just replace it or do I buy assembly as a whole with master and slave? Thanks for all your help
Much better. You can just replace the slave, but without knowing that it's the slave that's the issue, (could also be the master) you may wind up buying parts twice or piecing it together. When I did mine, I did the whole thing, and am happy I did, but I know that it's kind of pricey. It was worth it to me to get it the first time.
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Old 07-07-2014, 09:46 PM   #18
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Can't argue with that. Gonna replace all. Thanks Again

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