T-90 rebuilt but....

Oilleaker1 wrote: Hawky, when you jumped in, you stepped on my foot!  You're a big help with the photos. Thanks buddy.  Since you didn't replace the bushing in the flywheel, that pretty much rules out the bushing being too tight.  Clutch adjustment with the right freeplay next.  You say it did not jump out of 2nd for the 1st 300 miles. Now it does. Again, I'd pull the top off and take a good look at things. If it has worn in and end float is now the cause, you will need to take it out and fix it. It's hard to advise you much farther without seeing it in person and moving things. The fellows here, myself included, will be glad to try and help you, just ask. Oilly

It's interesting that a 2nd gear fix would make much of a difference in the noise level. It's usually the transfer case. Leaks, Meh, they do that.

cal.bar wrote: UPDATE - I am trying to upload video (with no success), but I took off the top cover today and indeed the throw out bearing is not moving forward enough to fully disengage the pressure disk.  My clutch pedal has one inch of free travel and my clutch cable is about maxed out.   Not sure where/what else to adjust.   Odd that tightening the cable worked for a day or two, then stopped working.  What might this mean?

Is your pivot shaft between the transfer case and the frame in good shape. Are the pivot points on the transfer case and the frame worn? Are the holes on the pivot shaft slotted out? Is the clutch fork inside the bell housing in good shape where the clutch cable attaches?

The clutch system on a 2A has many points of wear that can cause erratic behavior. Any wear on even one point can affect clutch operation.

SE Kansas 46 CJ-2A wrote: cal.bar wrote: UPDATE - I am trying to upload video (with no success), but I took off the top cover today and indeed the throw out bearing is not moving forward enough to fully disengage the pressure disk.  My clutch pedal has one inch of free travel and my clutch cable is about maxed out.   Not sure where/what else to adjust.   Odd that tightening the cable worked for a day or two, then stopped working.  What might this mean?   Is your pivot shaft between the transfer case and the frame in good shape. Are the pivot points on the transfer case and the frame worn? Are the holes on the pivot shaft slotted out? Is the clutch fork inside the bell housing in good shape where the clutch cable attaches? The clutch system on a 2A has many points of wear that can cause erratic behavior. Any wear on even one point can affect clutch operation.

One thing I would be very concerned about regarding the 2nd gear popping out issue is when you are off roading and are using 2nd gear for compression braking such as going downhill.  From personal experience, going down a steep hill and your transmission "pops" out of 2nd into neutral, my first words were, sh*t...sh*t...sh*t... as I tried to get control using the brakes and get it back into gear so I could continue down the hill safely.

Fix your 2nd gear sooner than later.

OK - update.  I finally got it all back together today.  And... putting in the shim and reducing the end play to .015 did the trick.  No more slipping out of 2nd!  Of course, it goes without saying that I COULD NOT have done all of this without all generosity of wisdom available on this board.  I cannot thank everyone enough.  As I learn, I will continue to post and try to help those who come after me.