OK I got a"good" one here; Non slant BUT it is a Mopar built straight-6 (Jeep 4.0L)
The frame went to Hell on my 97 Wrangler. Over a 3 week time, I pulled the body set it on sawhorses, found a replacement frame (from a '99) painted the replacement inside and out the best I could (square tube, fed POR 15 thru all the holes I could find) and swapped EVERYTHING over to this new frame.
When it was all on the old frame the clutch worked great teh day before deconstruction.. 87K on Jeep, 27K on complete clutch;master/slave included.
I pulled the motor trans T case as 1 unit and set it in the new frame; without a body in the way, that made it an easy pull.

had I been dealing with a mechanical linkage clutch I could see some possible "pitfalls" where it could work on the old frame, but not the new one; this one is hydro so those pitfalls are moot.

Now it won't disengage at all. Pedal feels fine if maybe a bit stiff compared to before. I removed teh slave, no leaks, works when pedal pushed etc. I tried a prybar with a deep well socket in the fork to manually disengage it; no dice. Had my son in it rear wheels jacked up trying to put it in gear (eng running) while I tried to manually work the fork with the prybar from underneath. Nothing but "grind-city"; would NOT go into gear w/o shutting the motor off.

I have exactly 1 thought on the subject but not sure if there is anything that can be done w/o pulling it all apart (which I'm trying to avoid since the clutch worked fine 3 weeks ago and I obviously could not drive it anywhere with the Jeep in pieces)

I remember reading in some old manuals (FSMs maybe?) about NOT steam cleaning a motor/tranny especially a stick. I never knew why.
While I didn't steam it I did powerwash it (used well water not heated or anytrhing) but I used some BH 38 a butyl based cleaner on the engine; (trans/T case was clean as it came out)I'm wondering if the disc is "stuck" to the flywheel and the PP and if so HOW can I un stick it, w/o disassembly??? Push the pedal in with it in gear and it does NOT disengage; I may start it in gear and take it around the block. It always did shift OK w/o the clutch once moving.

Did you make sure the slave plunger lined up with the fork correctly..I had this prob. with my truck. I didn't line things up correctly, because of this my pedal felt stiffer than normal.
I think that I compounded things by messing up a seal because of this ... didn't work right until I got a new slave cyl.

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<img src="http://farm4.static.flickr.com/3173/2992308402_5481afb26e_t.jpg">

I was not thinking that would be an issue; I never unbolted the slave from the trans when I pulled the motor/trans/T case; i unbolted the master from the firewall instead; so how would it dislodge itself?

Problem solved (I think) i put it in 2nd started it up (pushing the clutch pedal had NO effect except for enabling the clutch safety switch) by the time I got to the corner I felt the disc release; yup somehow it was just "stuck"; it works again; (like people used to complain about Chrysler's "over" power steering; no "road feel"; this thing has never had much "feel" to the clutch pedal. Now, it needs driven again!

Volaredon,

I enjoyed reading this thread. At one point in my great truck rebuild I lived with clutches and forks so much I felt like a throwout bearing...mashed and spinning. I began working with the willys jeeps and owned a '46, 53, 59 truck, '47 wagon and 62 cj5. Mine would sit a while here down south and the summer heat and humidity would cause the pressure plate to stick to the flywheel. A quick release is to drive very slowly, in gear,(I used 2d) headfirst in to a tree or similar non movable object. Lots of pine trees here to practice on. When that didn't work, then it was time to take off the inspection plate and use a thin stainless putty knife between them. Yeh, I know all about why it is a bad idea, but you are talking jeep here, not a wimpy car. Lastly, the slave master cylinder can have fluid leak back past the piston internally and not come out the back for a long time. Of course yo don't get the full stroke, so no release. Glad you think you have it fixed and I can visualize how nice it would be to put in an engine and tranny with no body in the way!
rock
'64d100

Boy it felt GOOD to take the Jeep out; never realized how much I missed driving a stick!!! I've always preferred it over an auto. but since getting hurt and having to wear that "moon boot" (air cast) for nearly a YEAR Dr said no 3rd pedal. Damn. I will most certainly have this vehicle long enough to replace another clutch down the road; but at the minimum, I sure hope I can teach the kid how to drive a stick with the present clutch; I would hate to replace it and then have him blow a new one in learning!
The plans for the Volare are still for it to "grow" a shifter and 3rd pedal during reassembly!

and Rock, (others too) thanks for the input!

It seems OK; actually got a da#n ticket in it on the way to p/u my insurance cards from my agent; good thing I had previously called him like 2 hours before to "get it in the computer; so that yes technically I had insurance when I'd been pulled over; 72 in a 55; I told the pig that stopped me that having been used to driving a 3/4 ton pickup the ;ast 6-7 months, and that this Jeep had not been out of my subdivision in about 18 months due to a serious injury where the Dr refused to allow me to drive a stick, I just wasn't "used to" the charecteristics of my much smaller Jeep. didn't matter; a$$#@!e still wrote me I'm still PI$$ED!!!!!!

Off-topic just for a sec here, but I would like to point out that talking to cops won't really help much, nor is it required... save it for the courtroom.


Ok, back to the subject..

I used to have a 5 speed Jeep Cherokee, and that piece o' junk was always having clutch issues... found out why...

The paper seal they put in the lids of brake fluid containers fell out when I was topping the fluid, and it seated itself against the bottom of the reservoir, stopping flow completely... took me a week to figure that one out...




~THOR~

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1984 D100 Shorty Custom
Certified Auto Appraiser - RevItUp Classic Appraisals
President - Cherry City Bombers CC
Part of Tyrde-Browne Racing

That's totally awesome!