Clutch: Service and Repair

REMOVAL

1. Remove transfer case, if equipped.
2. Remove transmission assembly.
3. Remove clutch housing pan, if equipped.
4. Disconnect return spring from clutch release fork and clutch housing.
5. Remove fork rod assembly spring washer from pin, then the rod with adjusting nut, washer and insulator.
6. Remove clutch release bearing and carrier assembly from clutch release fork, then the release fork and boot from clutch housing.
7. Mark clutch cover and flywheel to ensure correct position during installation.
8. Loosen clutch cover attaching bolts one or two turns at a time to avoid bending cover flange.
9. Remove clutch assembly and disc from clutch housing.

INSTALLATION

The pilot bushing requires a grease which will stay in place during high temperature operation. A small amount of grease should be placed in front of bushing and inner surface should be lightly coated.

Clean the surfaces of the flywheel and pressure plate, making certain no oil or grease remains on these parts. Hold the cover plate and disc in place and insert a special clutch aligning tool or a spare clutch shaft through the hub of the disc and into the pilot bearing in the crankshaft. Bolt the clutch cover loosely to the flywheel, being sure that punch marks previously made are lined up.

To avoid distortion of the clutch cover, tighten the cover bolts a few turns each in progression until all are tight.

Guide the transmission into place, using care to ensure the driven disc is not bent. Use a floor jack to support the transmission so that the clutch shaft may be guided through the driven disc safely. Finally, adjust the clutch pedal free travel.