Clutch mystery solved

Most of you have heard me whine about the stupid clutch binding up at the worse possible times (like during a rock crawling demo at an expo in front of 100's of people). So anyways, I order basically the entire clutch linkage assembly to try and fix the problem. My hubby had a few minutes to put it on Saturday and couldn't understand the problems I've been having as he was looking over the lightly worn old stuff as it was being removed. It wasn't until he started putting in the new stuff that he noticed the frame is busted in half right below the linkage. The only thing holding it together is the assembly mounting bracket that's bolted to the frame. Little did we realize that the jeep was a disaster waiting to happen.

 

it pays to get under the Jeep once in a while......
glad you found it now rather than out on the next trail

 

Sounds like you got lucky there. If it were me, it would have broken while I was in front of the 100's of people and knowing my luck the whole front end of the Jeep would have ripped off or something. Did ya fix it yet?

 

We check and tighten everything each time I take it out. The clutch linkage was hiding the crack so no one could see it. I got lucky in a huge way that it didn't break while I wa cruising down the highway at 70mph.

 

Yep. Fixed for now. It's going to be great to get my new frame under it this winter!

 

Jeez, Louise!!!

 

Yikes. First time I've heard of an Intermediate frame breaking in the middle. This must be close to (above?) the rear hanger for the front spring? FSJs sometimes pull the hanger off of the frame there (when lifted a lot), but they don't break through the rail. Sounds like the result of too many Rat Patrol jumps (by some long past PO of course) ...

 

It's just in front of the rear hanger. The clutch linkage hid it from the top and the spring hid it from the bottom. I'm really not that hard on the jeep so it don't know what happened. I've never had more than 3 tires in the air at any one time and when I did it was in slow motion. I really can't recall any one thing that may have done it. Old age can be hell even for jeeps.

 

I'd expect that if one caught air a lot, that if the frame were going to break, it would break there. That would be the hinge point - and the CJ's stiff springs could apply a lot of bending force to the frame. The more typical break is just behind the front crossmember, but I think that's more of a result of repeated twisting (fatigue) than impact. I've seen the front axle housing break, and would expect that before the frame breaks, but as you say, old age... plenty of surprises with old cars.

 

i had a '75 frame break in half just in front of the rear spring hanger. that made for an interesting drive back to camp. every time i hit the breaks it would open the crack and it would act like rear stear............ take it from thereR)

 

Jeep Gal, you mentioned a new frame this coming winter..what are you going to use? new replacement or reconditioned vintage?

 

Reconditioned vintage. We are going to box it in, do the shackle reversal and wider springs then swap everything over. The new/used frame is laying in the back yard just waiting for fall.

 

Of couse we will need progress pics. YJ springs?

 

I would like to do the same thing for mine...when i can get a 76+ frame.

Ever hear of welding 1"x .25" flat bar..(maybe 1.5" im not sure unless im looking at it) along the entire length of the frame, top and botom to strengthen it? Seems i read that somewhere and it makes sense on the top and bottom for rigidity along the frame length. Maybe help with the very problem you had from occuring again.

 

Sure - that's called strapping the frame. I've seen it done many times for race Jeeps. IMO 1/4" thick is excessive - measure the thickness of the stock rail and use that. Double thickness should be plenty, and it should approximately match the width of the rail. You only need to stitch weld it; weld a few inches on each side, then skip a few inches more.

 

Yep. A friend who went to a 6" lift was kind enough to donate the springs from his 2 1/2" lift. He offered us the stock springs & the 4" springs to. Luckily some people can't throw anything away.