Clutch Disc: Service and Repair

CLUTCH DISC
REMOVAL
1. Raise and support vehicle.





2. Support engine with wood block and adjustable jack stand, so engine mounts are not strained (Fig. 4).
3. Remove transmission and transfer case, if equipped.





4. If pressure plate will be reused, mark position of cover on flywheel with paint or scriber (Fig. 5).
5. Insert clutch alignment tool through clutch disc and into pilot bushing, to hold disc in place.





6. If pressure plate will be reused, loosen cover bolts evenly only few threads at a time in a diagonal pattern (Fig. 6). This relieves cover spring tension evenly to avoid warping.
7. Remove bolts completely and remove plate, disc and alignment tool.

INSTALLATION
1. Check runout and free operation of new clutch disc.
2. Insert clutch alignment tool in pressure plate and clutch disc.





3. Insert alignment tool in pilot bearing and position plate and disc on flywheel (Fig. 7).

NOTE: Raised side of disc hub faces away from the flywheel.

4. Install cover bolts finger tight.
5. Tighten cover bolts evenly and a few threads at a time.

CAUTION: Cover bolts must be tightened evenly to avoid distorting cover.

6. Tighten clutch cover bolts to: 5/16 inch diameter bolts to 23 Nm (17 ft. lbs.). 3/8 inch diameter bolts to 41 Nm (30 ft. lbs.).





7. Remove release lever and release bearing from clutch housing. Apply Mopar high temperature bearing grease or equivalent to bore of release bearing, release lever contact surfaces and release lever pivot stud (Fig. 8).





8. Apply light coat of Mopar high temperature bearing grease or equivalent to splines of transmission input shaft (or drive gear) and to release bearing slide surface of the transmission front bearing retainer (Fig. 9).

CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of disc.





9. Install release lever and bearing in clutch housing. Be sure spring clips that retain fork on pivot ball and release bearing on fork are secure (Fig. 10). Also verify that the release lever is installed properly.

NOTE: Release lever is installed correctly, when lever part number is toward the bottom of the transmission. Also a stamped "1" in the lever goes towards the pivot ball side of the transmission.

10. Install transmission.
11. Check fluid level in clutch master cylinder.