Having trouble with the clutch on a 1991 Cherokee. Truck is a 4.0l, 4x4 with an AX15 manual transmission. The pedal has very little pressure. Roughly 90% of the time it will not go into gear without grinding. New clutch and master cylinder. Actually, the master cylinder has been replaced three times and the clutch twice under this event. Transmission shop just pulled the transmission and found no signs of leaking, but there are a few burnt/discolored spots on the clutch plate. They say this is why there is no pedal. Doesn't seem to me that burnt/discolored spots on the plate would have anything to do with the hydraulic system and/or lack of clutch pedal. Anyway, anyone have an idea as to what the problem may be? Thanks.

 

Welcome! Hey, not to distract from here, but there are some pretty smart guys up in "ask a question" thread. I mean you are cool, but they might not see you here.

There is a Flywheel, clutch disk, and pressure plate. If you meant "pressure plate", that's where the springs are that you would feel with your foot pressing in. If it's burnt and discolored, the springs could be shot. THAT could make it slip while you were getten on it in lower gears. (there use to be presses with a pressure gauge to see the pressure the plate has left)

"90% of the time it grinds" Some manuals need the correct, specific oil that does not pit the brass syncros. (so that might come up). After three master cylinders, two clutches, and no leaking at the slave gotta wonder...

 

Hello, make sure you are using quality parts. I had a similar issue with my 1991 after pulling the trans a second time i purchased a second clutch from anothor vendor. I found a difference of about 3/8 of an inch in the height of the pressure plate. After installing the second unit all of my low pedal issues were resolved.
In other words NO FLEABAY CLUTCH KITS!

good luck
B

 

That's allot. Did it slip?

 

DFlintstone,

Used your suggestion and added this to the "ask a question" thread. Thanks.

The clutch disk looks great. Both the flywheel and pressure plate have the burnt/discolored spots. All of the clutch components and master cylinder have been replaced. The truck exhibited the same problem before changing the clutch and master cylinder. The previous owner indicated he changed the clutch every 60,000 miles and it would have a great pedal after replacement.

Captainwoot,

The second unit was 3/8 inch taller than the first? That is a lot.

 

Assuming the hydraulics didn't leak and it were properly bled.

With those two above covered, I don't get why it's not slipping with a wimpy petal. I'm not aware of any adjustment there.

 

The only thing I can come up with is an incorrect part. What are the odds with two clutches and three master cylinders being swapped?

 

No not at all, just would not release. I dont think there was enough travel in the slave cyl to fully depress the pressure plate. Lots of grinding trying to grab a gear and very low to no pedal. I went backwards a couple of years and picked up a master cyl, slave cyl and clutch kit from an 89. This gave me the metal master cyl and i was able to make my own steel clutch line and ditch the plactic junk with the quick connect. In for almost a year now with no issues.

 

Captainwoot,

Do you recall the thickness of the pressure plate that worked?

 

No i'm sorry i don't even have the pic's anymore. I would just suggest a brand name replacement.