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Old 04-27-2014, 02:57 PM   #1 (permalink)
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Default clutch binding issues

i have read all the threads pertaining to this and they helped along the way, but nothing in them is helping now.

91 samurai 5 spd 4x4. clutch pedal started sticking, replaced cable, clutch, clutch pedal, pedal bushings, pedal bracket.

the pedal seems a bit stiff, then it binds about halfway through pressing it, then it releases to the floor. i have gone through 2 cables, 3 pedals and 2 brackets while trying to figure out what is causing the binding.

i have re adjusted the pedal and cable several times and also had a local transmission shop check my adjustments.

i am dropping the transmission and changing the release arm bushings and throwout bearing. while i have the release arm out i will check the fork and arm for damage. didnt see any damage on anything when i changed the clutch.

any help would be much appreciated since this is my fiances daily driver.
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Old 04-27-2014, 02:59 PM   #2 (permalink)
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not sure if it could be the entire pedal assembly that is bad
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Old 04-28-2014, 09:39 AM   #3 (permalink)
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Do a close inspection of the transmission input shaft housing. The aluminum that the throw out bearing rides on gets galled, causing the bearing to "stick" as it rides along it, on it's way to push against the pressure plate fingers.
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Old 04-28-2014, 10:50 AM   #4 (permalink)
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thanks a bunch azelgin. there is actually a small nick on the input shaft housing. its super small, but im still ordering a new one. i just put the new release shaft bushings in and the realease shaft barely moves now. thinking i might as well change the release shaft too. also i noticed the release spring is broken. i think im on the right track, just getting tired of dealing with it
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Old 04-29-2014, 03:50 PM   #5 (permalink)
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ok, so i ordered a new release spring and shaft. william at lowrange doesnt think i need to replace my input shaft housing after looking at the pictures. so im stoked on that. gonna put a new release bearing in and a new cable. hopefully this fixes it. i have a new lift to go try out.

thanks again azelgin for the help
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Old 04-29-2014, 04:08 PM   #6 (permalink)
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Quote:
Originally Posted by GotEm View Post
ok, so i ordered a new release spring and shaft. william at lowrange doesnt think i need to replace my input shaft housing after looking at the pictures. so im stoked on that. gonna put a new release bearing in and a new cable. hopefully this fixes it. i have a new lift to go try out.

thanks again azelgin for the help
I've got one of my Samurai with a clutch like you had. Push, push, push and whump, it goes to the floor. Very annoying. My 86 has a rebuilt transmission in it. I noticed the galled up shaft housing, but decided to smooth it up with some sanding. Seems to have worked.
Let me know how the shocks work out. I looked up the numbers you put up and might give them a try. About 1/2 the price of the OME.
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Old 04-29-2014, 04:44 PM   #7 (permalink)
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thats how william talked me into them. ill let you know for sure. gonna put the suspension together thursday
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Old 04-29-2014, 05:22 PM   #8 (permalink)
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The Petroworks rebuilt transmission I put in my Sami had a brass collar on the input shaft housing. I'm guessing they machined a stocker down and then pressed the brass collar on it.

Maybe something a machine shop could do.

Seems like a permanent fix.
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Old 04-29-2014, 05:35 PM   #9 (permalink)
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Quote:
Originally Posted by VaderSS View Post
The Petroworks rebuilt transmission I put in my Sami had a brass collar on the input shaft housing. I'm guessing they machined a stocker down and then pressed the brass collar on it.

Maybe something a machine shop could do.

Seems like a permanent fix.
Cool! I'll be cruising plumbing isle at Home Depot. Should be able to come up with some copper pipe and epoxy, to fix that sucker up just fine. I'm thinking a brass sink tailpiece and some JB Weld will be just the ticket!
If not, I wonder if they sell just the input shaft housing?
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Old 04-29-2014, 05:41 PM   #10 (permalink)
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Cool! I'll be cruising plumbing isle at Home Depot. Should be able to come up with some copper pipe and epoxy, to fix that sucker up just fine. I'm thinking a brass sink tailpiece and some JB Weld will be just the ticket!
If not, I wonder if they sell just the input shaft housing?
Suzuki Samurai Transmission Front Input Housing Bearing Retainer

there ya go. brand new just the housing
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