1986 XJ 2.5L Clutch Chatter Repair. Part 4.

Made a couple of small Jeep specific tools for pulling a broken index pin from the rear of the 2.5L engine block. The broken pin kept the engine and trans from mating perfectly to each other. In fact it left a gap between them. I modified an air tool hose fitting by taping the inside with a 1/4-20 thread. A 1/4-20 bolt screws the slide hammer to the air fitting, allowing the slide hammer to pull the damaged index pin from the engine block.

1986 XJ Clutch Chatter Repairs. Part 3.

Bent up a nice titanium flat spring for the clutch release arm. Ti is a super tough material. It bent nicely around various diameter sockets clamped in a vice. Used 3/16″ diameter rivets that broke my rivet gun. Also pulled the bell housing off the AX-5 trans so that a locating dowel could be machined to make sure the trans will locate accurately to the engine.

1986 Clutch Chatter Repairs. Part 2.

I’m so happy to have this clutch arm repair moving forward. Turned two 1/4-20 bolts into pins for the release arm. The factory pins were sheared completely off the arm when the old throw out bearing went bad. From what I could tell, they were tiny. These are about .167″ in diameter. They allow a little play with the new throw out bearing that has bigger engagement holes for the pins.