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Old 08-19-2014, 01:22 PM   #1
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1993 YJ Clutch Issue

Forgive me if this has already been posted, I did a search and finally decided to just register because I didn't find what I was looking for.

My daughter owns a 1993 4.0L 5 Speed Wrangler. We recently put in a new Luk clutch kit (thanks to this forum it help alot). Took it for a test spin and there were no issues. Daughter took it down to the muffler shop to have the exhaust put back on (was rusted so had to cut it off). After that she noticed that she couldn't keep the Jeep in 2nd or 4th gear, it just keeps popping out and now I am afraid she is going to burn up the clutch because she holds it in 2nd or 4th to keep it from popping instead of bypassing those gears (not her fault she didn't know what to do). She is supposed to leave for Florida tomorrow to go back to college.

I need some help quickly, what could be the issue?

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Old 08-19-2014, 01:33 PM   #2
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Does it just need some more adjustment?

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Old 08-19-2014, 02:34 PM   #3
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Usually if it is jumping out of the 2 back gears 2nd and 4th. That means something isn't lined up quite right, and the shifter is hitting the body. Most common with a YJ that has a body lift on it.

You can try taking the floor pan out of it, and take it for a ride. If it cured the problem, then you just need to trim the pan to keep it from hitting. If it didn't cure the problem, then I would say the synchronizers are going in those gears although 4th is an extremely odd gear for the synchronizers to go bad. Most common are 2nd and 3rd.

There is no adjustment on a hydraulic clutch. Other than bleeding the system to get all of the air out. If you can start the vehicle and then shift into 1st gear without any grinding, that is a sign that the clutch is bled out properly.
'87 YJ, 4.2L built and bored, 8.5" of lift, 8.8 rear, AX15/NP 231, Tom Woods drive shafts, Flat fenders, 12,000LB winch, Custom bumpers, Rattle can paint job. Never completed...
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Old 08-19-2014, 02:43 PM   #4
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Okay, thank you. Yes it has a Rough Country body lift. I will let my husband know so he can take a look at it tonight. Thank you for the quick response.
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Old 12-29-2014, 10:46 AM   #5
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Thanks OIIIOforlife, Saved me from a disaster in the clutch department, did not know there were no adjustment for the clutch,
Gary in southeast NC.
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Old 12-31-2014, 11:56 AM   #6
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I was wondering if she drove it awhile and there was no problem until she had the exhaust fixed, if they could of bent something or it is hitting the new exhaust causing it to pop out?
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Old 01-01-2015, 05:16 PM   #7
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Holding it in gear so that it does not pop out of gear is not going to hurt the clutch at All, in fact I would say, that is the thing to do, if you bypass 2nd and 4th, then you can burn the clutch by slipping it for the higher gear. Just Me!

Wow I just saw this is an OLD post, LOL

The Government can not give anything to anybody that it does not first take from someone else !
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