Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 11-14-2016, 12:08 PM   #11
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Quote:
Originally Posted by hdgapeach View Post
Not trying to be the “glass half empty” guy, but I’d be worried about shearing the threaded ends of the solid shaft. You didn’t show a proposed diameter of those stud ends. I don’t know the force numbers exerted on the mechanism by the clutch fingers. I do know it’s enough force to pop the mounting bracket off the firewall. That has happened to me once on my first CJ5, back in the 80’s. I had to drill through the firewall and through bolt the bracket with a wide backing plate to stiffen up the area. My troubles were created by me by installing a body lift and NOT correcting the bell crank angle in relation to the frame.

A lot of engineering went into the design of the original design and has worked pretty well (IMHO) considering how old these rigs are. I don’t like the issues with the system either, especially when you perform modifications to the vehicles like we do. Anything that alters the perpendicular orientation of the bell crank will cause additional stress to the system (ie; body lift, drop skid plate spacers). Any mods that alter the position of the bell crank creates a need to remedy that angle. I had to fabricate a drop bracket for the firewall when I installed a 1” body lift to correct the induced angle on the CJ5 I have now. Along with that modification, I added an adjustable length clutch rod.

I believe many of the issues are brought on by us not performing needed maintenance on the stock setup. There’s a reason the original hollow tube has a grease fitting. Along with that comes the need to clean that system every now and then, replace worn parts and re-grease with new lube. The bushings eventually wear and need replacing. I’ve never had to replace the “paper clips”. The only job for those clips is to keep the bushing studs from coming out of the tube. There isn’t a whole lot of stress exerted on those clips until you modify the system and create the stress by not correcting induced bell crank angles.

You figure out how to make a system using grease-able tie rod ends on each end of the bell crank, I think you’d be headed in the right direction! Until then, either the system BusaDave9 uses, or a hydraulic clutch, is the way to go. I installed the same system BusaDave9 did and have had no problems (so far, after correcting the bell crank angle).

Good luck, and I admire your thinking on this. And apologies for the "dissertation"!

The OEM clutch linkage was designed by AMC 'bean-counters'. Made as cheap as could be from inferior steel that was soft and wore quickly. Would wear even faster when the pivot points became coated with desert dirt.
On the bellcrank. I lathe turned a full tube length silicon bronze bushing to replace the 2 nylon/plastic OEM bushings.
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Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 11-14-2016, 02:41 PM   #12
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Vehicle(s): Right now, only one '76 CJ5. 304 with a three speed stick. Everything else is pretty much stock 'cept for a 4" suspension lift. Came to me with a back breakin' 4" suspension lift attached to a reverse shackle setup (Reversed the reverse shackle crap and now she rides like a Caddy!) Also posess a few 60s & 70s Mustangs and a couple of late 70's F150s 4X4s.
 
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That's why I said "worked pretty well considering...". It's amazing the complicated design and price point materials work and last as long as they do. And you can make the original stuff last quite a bit longer if you do some hands on preventative maintenance every now and then.

I can only imagine how the sand blasting in the desert quickly erodes the metal. I'm only familiar with the swamp mud and clay over here in the south east!

Biggest wear location on my rig was the pedal rod where it attaches to the bell crank. The end was worn over half way through when I switched over to the heim setup. That would've been a good place for AMC to spend another dollar or two.

Can't complain too much, though. The original lasted since '76!

 

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Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 11-14-2016, 02:59 PM   #13
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Same major wear point on mine. Mine almost wore through in 3 yrs. I play in the sand a lot.
I swear, the whole OEM assembly was made from mild hot-roll steel.
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Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 01-10-2017, 12:53 AM   #14
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My 78 cj5 has a chain setup and it has a 5.0 ford motor when I leveled the motor in the frame it won't release the clutch the rod attached to the pedal bends a lot and it's very hard to push , result no clutch at all! Any ideas on the best and least expensive hydraulic assembly? Please!

 

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Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 04-03-2017, 12:04 PM   #15
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A BIG X2, that kit is the bomb!

 

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Default Re: Opinions/Options on Clutch Linkage Redesign 

Old 04-03-2017, 12:20 PM   #16
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A BIG X2 on that kit, it is rock solid!
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