"Have you tried to start the motor with the jeep in gear, clutch to the floor, brakes applied? Will the motor freely spin or is the clutch wholly "connected"?"
I tried this the other day and it lurched and was in gear - didn't start as the brakes were applied. But got to thinking about the possibility the clutch disk might be 'stuck' to the flywheel. I installed the clutch 4mos ago and its been sitting ever since. I have had (or think I've had) some friends that let their jeep sit outside for a long time (years) and the disk kind of rusted or stuck to the flywheel. The manage to break it loose by starting it gear a few time. So tightened the clutch as much as possible, pedal in put in gear and started. Took a couple tries of lurching but then it started and didn't go anywhere. Don't know if it was really stuck to the flywheel or if the pressure plate needed a little 'bump' to free stuff up. You could here grinding the clutch a bit for a second then all good. Reset the clutch cable to proper length, Seems to be working ok in 3 ft garage test in all gears, high and low, 4wd and gear splitter/OD. First gear is tight as hell - other shift ok. I was worried I might have damaged one of the synchronizers when driving in the rear bearing and setting proload (went way to high before I realized) and that might be causing those issues...hopefully it will loosen up a bit over time - but it doesn't grind so it should be ok. Its still making the clunking sound that it made before - a main bearing may be going...
Off to the store to find a snap ring to hold the OD shifter cane on - I had it just the other day. So far that is the only piece I have mis-placed in the project. Then I can test it around the neighborhood.
Thanks for ideas fellas - it helps me to think 'aloud' on here sometimes...