The clutch linkages tend to "saw" into each other over time.
The rod may have a deep groove cut into it, top or bottom end, or the bell crank holes may be mega elongated. Over time they will saw away at each other and get harder and harder to push. Eventually one or the other will saw thru and the linkage will fail!
Normally this happens in stopped traffic, suddenly the clutch pedal hits the floor, and you are eagerly on the brake to avoid smacking the guy in front of you!
Must keep good linkages, keep 'em greased and oiled. Or break down, like me, and modify the links with real bearings at the pivots.
You should have "1 inch" of free play in the pedal before you feel the throwout bearing contact the pressure plate.
Got my 1st (bought all by myself) CJ-5, a '77 w/ 304. When I got in 1st Ranger Battalion back in early '83, Prior to that I had a '76 hand-me-down abused old beater given to me.
Had nothing else for a daily driver since. Total 6 CJ-5s and a Willys.
I presently have the '77 CJ-5 and '46 Willys that I bought in '91, I'm not in the "Find the Limitations Mode" anymore, as with the other 5 I once had, I tend to care for these 2 like a Mother Hen (all the well still knowing their full capabilities!)
I liked the paint scheme on the 1st '77 so well, I pretty much duplicated it on my present '77. I've made many upgrades to this '77, It's pretty much like a '79 w/ swapping heater/ vent systems out (better system) Upgrading to Motorcraft Ignition (as in a '79) and many other upgrades including a homemade extra heat heater ("The Sahara Breeze!")
You DID NOT separate the tranny from the transfer case? Nor did anyone else?
Bellcrank on backwards?
pics/ 1st '77/ same Jeep (back when Rangers only wore the black beret!)/ Next '79 (semi got the last one)/ Present '77, ("Mr. Jeep")/ Present '46 Willys ("Willy")/ No title necessary!/ Next 3, few shots of my mancave!/ Adjust clutch linkage/
Images (Click to enlarge)
Sunday, November 20th, 2016 AT 12:22 PM