82 fj40 help (1 Viewer)

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Jun 7, 2015
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Thoughts? Clutch?

I have an 82 FJ40 with 99k original miles.
Bone stock under the hood. I had experienced reduced power, and the carb was leaking at the base so I assumed it was time for a rebuild.
Dis-assembly, Ultrasonic cleaner, new needle valve and spring, new gaskets, new accelerator pump. Adjusted and dialed in at 700rpm smooth idle.
Drove for about a week with little to no change to the loss of power.
i.e. Push the gas and the engine revs unitl high enough RPM's then start to feel it catch and gain back some energy.
Today it got much worse, nd now i can put it in gear, let off the clutch, and there is 0 change. doesnt bog down, doesnt move, doesnt die - just nothin but idle.
if I rev high enough it will move, but just slightly.
I never smelled the clutch burning, so was not sure, but starting to think that has to be it.
Thought I would get some input in the meantime.
thanks all
 
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Pic of clutch pressed and depressed.
Apparently trans input shaft has been leaking for a while.
Fluid is full and fairly clean. the backside of the clutch plate from what I can see is also completely dry.
Any thoughts?

Clutch pedal up:
20250421_102704.jpg



Clutch pedal down:
20250421_102622.jpg
 
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Ok so now the engine runs great - idle to full rpm's. So there is clutch adjustment at slave cylinder and its correct. You bleed the system, yes. Well I think the clutch disk is shot. Look into pilot and throw out bearing, clutch disk, pressure plate, maybe rear engine main seal. You might have a bad seal between tranny/transfer, there is a by pass hose that lets the pumped up to tranny fluid return to transfer. But if you are taking the T/T out put in the seals.
 
I have seen input shafts to tranny broken, it might had enough interference to transmit power for a while due to uneven break.
 
Is there slack in the clutch pedal, or is it completely tight when you press it? There should be inch-ish of slop in the pedal.
 
Is there slack in the clutch pedal, or is it completely tight when you press it? There should be inch-ish of slop in the pedal.
Yea, there is a little play before you feel the movement
 
My son destroyed the clutch in my 68 some how. Only thing I could think of is he held pressure on the clutch pedal that allowed it to slip a little and glazed the flywheel and pressure plate until it couldn't grab the disc. I would set a mirror under the inspection cover opening in the bell housing. Then with a person at the steering wheel and another off to the side while running, foot off the clutch pedal and in gear verify the pressure plate is spinning. If so if the pressure plate spinning you either have a clutch disc that's slipping or issue with the transmission input shaft. Either way you are going to have to pull the transmission and transfer case. If the pressure plate isn't spinning you have a major problem with the crankshaft. Less likely for the crankshaft to have a problem.
 
My son destroyed the clutch in my 68 some how. Only thing I could think of is he held pressure on the clutch pedal that allowed it to slip a little and glazed the flywheel and pressure plate until it couldn't grab the disc. I would set a mirror under the inspection cover opening in the bell housing. Then with a person at the steering wheel and another off to the side while running, foot off the clutch pedal and in gear verify the pressure plate is spinning. If so if the pressure plate spinning you either have a clutch disc that's slipping or issue with the transmission input shaft. Either way you are going to have to pull the transmission and transfer case. If the pressure plate isn't spinning you have a major problem with the crankshaft. Less likely for the crankshaft to have a problem.
Thanks, Yea the pressure plate appears to be spinning
 
If the transmission and transfer are both in gear you most likely pulling the transmission to figure it out. Since it seems to have happened over a period of time I doubt it's the transfer case in neutral
Agree, seems like a clutch to flywheel issue
 
Pulled the clutch - pics attached
Very worn with hot spots on the flywheel and pressure plate.
Also looks like small rear main leak as well as Trans input shaft leak

20250423_122007.jpg


20250423_122000.jpg


20250423_121955.jpg


20250423_121921.jpg
 
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Clutch disk is worn down to the rivets in many places. Input shaft splines look a little chewed, pilot bearing area looks corroded too. Pressure plate has some hot spots and some damage.
 

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