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Old 04-08-2012, 11:04 AM   #1
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clutch problem on 89 YJ 2.5

Problem is can not change into gear when engine running. Smooth gear change when not running. Can start in reverse or first with clutch depressed and move off smoothly on releasing clutch, can double declutch into second and third with a bit of crunching. Have replaced master cylinder and bled thoroughly with no change in symptoms.
Note that this first happened when i tried to reverse out of a parking spot in deep snow without clearing it first - in 4WD (posilok fitted) - I think I remember a bit of a clunking noise and I stalled. On restarting it would not go into gear.
If I engage 4 wheel drive the symptoms appear a bit worse as I can not get out of first gear even with double declutching.
Are there any simple tests that can be done to narrow down the problem.
If I have to remove the transmission what all should I plan to replace when I am in there.
Thanks for any insights.

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Old 04-08-2012, 11:21 AM   #2
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if you time it right, can you float the transmission into any gears while rolling?

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Old 04-09-2012, 01:19 AM   #3
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how is the hydraulic fluid? is any leaking?
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Old 04-10-2012, 10:14 AM   #4
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in reply to previous questions:
1. no evidence of fluid leaking (although the reason I replaced the master cylinder was that there seemed to be fluid leaking inside the car where the clutch pedal linkage entered the cylinder) - I have replaced it with a metal cylinder not the plastic type.
2. I can start the jeep in first and drive off. By double declutching and getting the revs right I can change up through the gears and back down again - but this procedure could not be described as smooth - although it sounds and feels clunky rather than crunchy or grinding. I can brake to a halt in second gear and hold it on the clutch without stalling.

also pumping the clutch does not seem to change anything at all.
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Old 04-10-2012, 10:46 AM   #5
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slave cylinder
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Old 04-11-2012, 09:39 PM   #6
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x2 on the slave cylinder. too bad its internal hate the guy that designed it. good luck changing it. not too bad, just takes time
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Old 04-12-2012, 11:22 AM   #7
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is it worth another bleed before attacking the slave?
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Old 04-12-2012, 11:33 AM   #8
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it wouldnt hurt. is there brake fluid leaking from the bell housing?
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Old 04-12-2012, 12:47 PM   #9
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Sure sounds like it might be the slave cyl... Is the fluid level dropping in the MC?

FWIW if you can get into 1st gear, then you don't need the clutch. It's all about rev matching

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