Modified XJ Cherokee Tech XJ (84-01)
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Clutch Issues - So Sad

Old 02-16-2019, 05:36 PM
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Default Clutch Issues - So Sad

have found some posts about clutch problems. But nothing quite fits this.

Major step forward. Major step back in the build.

Installed a SYE. Swapped the NP231 t-case for a reman with the SYE already installed. Also installed a Tom Wood's custom propeller shaft.

But then disaster. The clutch on the AX15 basically will not disengage.

At full stop, engine off, clutch pedal to the floor, in first gear, attempt to start XJ, vehicle lunges forward.

At a full stop, in neutral, clutch pedal to the floor, cannot shift into first gear. Must turn off the vehicle to get the vehicle into gear.

Clutch ins't slipping. Full power with acceleration.

Can "power shift" (shift without the clutch) from first through fifth at the proper speed/engine RPM.

1991, AX15 5 speed, 4.0 Litre, 4X. Internal cylinder on the AX15 :^(

Prior to install of reman t-case, clutch pedal was a little sloppy, shifted fine, full power, disengage without issue, engaged fine.

Please advise. Please help. Major buzz kill.
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Old 02-16-2019, 06:49 PM
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I would try and bleed the slave cylinder first. If that doesn’t work then sounds like a new slave and or master cylinder is needed.

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Old 02-16-2019, 06:57 PM
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Originally Posted by mikebravo View Post
I would try and bleed the slave cylinder first. If that doesn’t work then sounds like a new slave and or master cylinder is needed.


Just made an attempt to bleed the cylinder... I think. It looks like a line protruding out of the back of the internal slave cylinder with 16 mm and 11 mm nuts.

Any idea if that is the correct part?

Felt like I was going to turn the corners on the "fasteners." So I stopped. Will have to blast it with PB a few days in a row then try again.

Patience sucks.
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Old 02-16-2019, 09:14 PM
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Different vehicle but when my 96 Nissan Hardbody was doing this one of the springs on the friction disk came out and was lodged between the disk and pressure plate keeping the clutch from disengaging. I know that's not what you want to hear but if these have the same type of clutch it's something to keep in mind.
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Old 02-16-2019, 09:38 PM
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Do yourself a HUGE favor, and find a 94+ bell housing, clutch fork, and the front throw-out bearing support from a 94+ AX15.
Up to 1993 had an "internal" slave cylinder inside the bell housing.MAJOR PAIN IN THE AR$$!
1994 they changed it to an external slave cylinder. The 94+ make changing out the slave cylinder much easier for future repairs.
So you can find people selling complete "kits" on fleabay, or the Wranglers with AX15s had the same set up as an XJ too.
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Old 02-17-2019, 04:19 AM
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Originally Posted by Rlmx View Post
Just made an attempt to bleed the cylinder... I think. It looks like a line protruding out of the back of the internal slave cylinder with 16 mm and 11 mm nuts. Any idea if that is the correct part?
When I wake up in the morning, I think about God, my wife, my kids, my job, and the flipping Jeep.

I have learned that the line protruding out of the back of the internal slave cylinder with 16 mm and 11 mm "nuts" or "fasteners" (I dunno what to call it) is the place to bleed the internal slave.

Just for the record.
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Old 02-17-2019, 04:19 AM
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Originally Posted by DustyWagoneer View Post
Do yourself a HUGE favor, and find a 94+ bell housing, clutch fork, and the front throw-out bearing support from a 94+ AX15.
Up to 1993 had an "internal" slave cylinder inside the bell housing.MAJOR PAIN IN THE AR$$!
1994 they changed it to an external slave cylinder. The 94+ make changing out the slave cylinder much easier for future repairs.
So you can find people selling complete "kits" on fleabay, or the Wranglers with AX15s had the same set up as an XJ too.
Thank you.

Investigating this for sure.
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Old 02-17-2019, 08:28 AM
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Look at your clutch pedal and see if it's ripped at the weld.

If it's a bleeding issue, you'll have brake fluid dripping out of the bell housing or inside the cab on to the fuse box.
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Old 02-17-2019, 11:13 AM
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I second cruiser's suggestion, especially if you get no pressure even with pumping. On my '88xj weld went with a pop while shifting, welded it back up (had to pull pedal assy. out, not hard) and good to go. While the internal slave is not the best design, in 390K+ miles I have only had to access mine twice, works fine rest of time.
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Old 02-21-2019, 01:33 AM
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Tried again to open the bleeder valve. Couldn't for the life of me because I felt like I was going to turn the corners and make all worse. Took the XJ to a trusted mechanic. He told me the master was leaking. Had a Luk master on hand. He installed it for $100. Back on the road. Clutch is solid. Clutch pedal is fine.

On with the build.

Rear shackle relocation kit install this weekend! Totally hyped. Just about finished with all the work on the belly side of the beast!
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Old 02-21-2019, 08:25 AM
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Glad I was wrong and it wasn't the disk itself.
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