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Old 09-01-2012, 07:56 PM   #1
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clutch/tranny issues

Hey guys, long time reader, first time posting on here. I just picked up my second Jeep back in April, it's a 98 Sahara 5 speed. Only 89k on it as of today, bought it from a buddy and got a pretty good deal.

Anyway I was driving today and as I was coming to a stoplight I went to downshift. I pushed in the clutch about halfway, and then it kinda broke loose and hit the floor. I was able to pop the tranny into neutral and coast into a gas station. I jumped out and looked underneath to see if any fluid was leaking or if anything visually looked out of place. Everything appeared to be ok. Jumped back in and went to mess with the clutch pedal, it was back up off the floor. I tried pushing it again, and it seems to be frozen. Every time I applied pressure to the pedal with the engine running, I also heard what to me sounded like a mild grinding or rubbing, like something is bound up. So I shut the jeep off and called AAA, then went into the gas station for a cold drink. When the tow truck got there, the driver attempted to start the Jeep. he was able to push the pedal in enough to engage the safety switch, but the engine only turned over a couple of times before it seemingly bound up and the starter wouldn't turn the engine over. What could I be looking at here? My first thought was either a master or slave cylinder, but with the apparent binding I'm at a loss. I consider myself to be mechanically inclined, but I thought I'd post here to see if anyone has had a similar issue to save myself a little time, or to at least give me some direction as I have not had to tear into a manual transmission as of yet. Sorry for the novel, let me know if I left anything out that you might need to help diagnose the issue.

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Old 09-01-2012, 09:22 PM   #2
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you have no mechanical lingage that releases the clutch except the master cylinder rod that attaches to the clutch pedal arm..when you push the clutch pedal it in turn pushes a rod into the master cylinder..this in turn applies hydraulic pressure from the master cylinder to the clutch slave cylinder..this makes the slave cylinder extend which in turn releases the pressure plates pressure on the clutch just as a mechanical throw out bearing would..I would just tear into it and see what is what..

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Old 09-02-2012, 01:48 PM   #3
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Yeah I guess that's what I'm going to have to do. I havent looked in the book yet, but does the tranny have to come out to get to the slave?
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Old 09-02-2012, 06:11 PM   #4
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So, I pulled the master and slave assembly. Once I pulled the slave out, the clutch pedal was immediately freed up. I stuck my hand in the hole, and I was able to push and pull that piece the slave plunger sits in freely. There was little to no resistance either way. Of course, I could only get my finger so far in there, so I don't know if I covered the whole range of movement or not. Shouldn't there have been some resistance? Seems to me I am looking at something internal, as pulling the slave out of the transmission immediately changed the way the pedal behaves. There was some minor damage to the slave as well, in relation to the retaining clip that held the white plastic thing. Now since I pulled it all the way out, I figured I might as well go ahead and replace it. However, I went to several parts stores and nobody carries or can even order the master/slave assembly, they only sell each part seperately. Not quite sure how to proceed from there, I will do some digging and see if I can order the assembly online anywhere. If not, how should I handle the replacement? I'm sure there's probably a write up somewhere, if someone can point me in the right direction that'd be awesome! Do you guys think this is probably an internal issue as well? It seems to me that whatever was causing the clutch pedal to be stuck has to be in relation to the clutch assembly itself. Also, after taking out the slave the Jeep started just fine, but that was also after sticking my finger in the hole and moving stuff around.
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Old 09-02-2012, 07:41 PM   #5
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Something happened in there, I don't think a new slave cylinder will fix it.
Maybe busted the throw out bearing. If the rod pushed in so far that it kept the motor from cranking over, there's definitely something else besides the rod slipping out of the cup.

If it makes you feel any better, I found needle bearings on my oil plug. So I'm not rolling in the fun either.
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Old 09-02-2012, 11:04 PM   #6
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Yeah I kinda figured that, but wanted a second opinion. Now, since the trans is going to come out what's a good clutch setup to go with? Any respectable kits out there that'll give me everything I need?

Full spool, as for your issue... That doesn't make me feel any better man. Other than the needle bearings, did you have any metal shavings in the oil or any weird noises? Hope you get it figured out!
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Old 09-04-2012, 12:16 PM   #7
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Ordered a new Luk clutch kit, part 05-065, on eBay for $96.55 shipped. Supplier is "autopartsexp" for anyone else looking for the kit. I also ordered a new master/slave assembly, AMS AUTOMOTIVE PS0119-3, for $113.35 shipped. Supplier for that part is "bestautopartstogo." I also bought a tow bar from walmart and installed it yesterday, since the bill from the towing company was going to be close to the cost of the tow bar. Got the jeep moved from the in laws house (where I had it towed originally, using my brothers AAA membership) to my house, and parts should arrive on Monday. I hope to get the transmission pulled by the weekend so that when the parts arrive I can get everything put back together. Anything else I need to be looking for when I pull everything apart?

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