Clutch not fully disengaging.

[gogmorgo]

Something I was told in school (but am only just remembering) in reference to this is a used flywheel gets worn down around the inside, but not where the clutch bolts to it. This means that a new clutch bolted to the worn flywheel has the pressure plate springs pushing further towards the end of their travel, meaning they need pushed further before they lift the clutch disc off or something. I also remember one of the other techs in the shop where I apprenticed having a hell of a time getting the clutch adjusted correctly after replacing it when the trans was out for unrelated reasons, then it went out of adjustment by the next inspection, and this time it couldn’t be made to happen until the flywheel got resurfaced. Ancillary memory, I wasn’t the one doing the work in either case. Just wish I’d remembered sooner. 
 

Not only does my ZJ’s clutch only disengage right on the floor, the pedal is also a lot heavier than other clutches I’ve got, including in my 3/4 ton GMC. I assumed it was just a ZJ thing, but now I’m suspicious that a new flywheel is going to be in my not so distant future. 

[Dickinson County Comanche]

25 minutes ago, gogmorgo said:

Something I was told in school (but am only just remembering) in reference to this is a used flywheel gets worn down around the inside, but not where the clutch bolts to it. This means that a new clutch bolted to the worn flywheel has the pressure plate springs pushing further towards the end of their travel, meaning they need pushed further before they lift the clutch disc off or something. I also remember one of the other techs in the shop where I apprenticed having a hell of a time getting the clutch adjusted correctly after replacing it when the trans was out for unrelated reasons, then it went out of adjustment by the next inspection, and this time it couldn’t be made to happen until the flywheel got resurfaced. Ancillary memory, I wasn’t the one doing the work in either case. Just wish I’d remembered sooner. 
 

Not only does my ZJ’s clutch only disengage right on the floor, the pedal is also a lot heavier than other clutches I’ve got, including in my 3/4 ton GMC. I assumed it was just a ZJ thing, but now I’m suspicious that a new flywheel is going to be in my not so distant future. 

That clutch is buttery smooth. I went to move my 86’ with the external slave AX-5 and it was harder to push in than my ZJs, and it even has the little return spring removed. It’s not quite as nice as my 89’s with the internal slave, but it’s pretty close.

[Dickinson County Comanche]

28 minutes ago, gogmorgo said:

Something I was told in school (but am only just remembering) in reference to this is a used flywheel gets worn down around the inside, but not where the clutch bolts to it. This means that a new clutch bolted to the worn flywheel has the pressure plate springs pushing further towards the end of their travel, meaning they need pushed further before they lift the clutch disc off or something. I also remember one of the other techs in the shop where I apprenticed having a hell of a time getting the clutch adjusted correctly after replacing it when the trans was out for unrelated reasons, then it went out of adjustment by the next inspection, and this time it couldn’t be made to happen until the flywheel got resurfaced. Ancillary memory, I wasn’t the one doing the work in either case. Just wish I’d remembered sooner. 

It almost was like the flywheel had been resurfaced but not shimmed to match. It was ever so slightly thinner than the new one (only about .010-.025 or so)

[pizzaman09]

I just did the internal slave to external slave conversion in my Comanche, the external is undoubtedly heavier, however it is not very heavy.  Very heavy hydraulic clutches I've been around included an 06 Ford Mustang V6 and any Subaru WRX.  

[Dickinson County Comanche]

2 hours ago, pizzaman09 said:

I just did the internal slave to external slave conversion in my Comanche, the external is undoubtedly heavier, however it is not very heavy.  Very heavy hydraulic clutches I've been around included an 06 Ford Mustang V6 and any Subaru WRX.  

Oh no, it’s not heavy by any means. My dads 96’ 2500 dodge and the many grain trucks with mechanical clutches I’ve driven have been significantly heavier. A light clutch is a must for me tho, just bugs me when something is unnecessary hard (like it was before)