REMOVAL & INSTALLATION
See Figures 1 through 16
- Remove the transmission and transfer case from the vehicle.
- Remove the flywheel housing.
- Matchmark the clutch pressure plate to the engine flywheel with a center punch so the clutch assembly may be installed in the same position after adjustments or replacement are complete.
- Loosen the clutch pressure plate retaining bolts equally, a little at a time, to prevent distortion and relieve the clutch springs' tension evenly. Remove the bolts.
- Remove the pressure plate assembly (bracket and pressure plate) and driven disc from the flywheel. The driven disc will just be resting on the pressure plate housing, since it usually is mounted on the input shaft of the transmission, which has been removed. Be careful that it does not fall and cause injury.
- The clutch release bearing (throwout bearing) is lubricated at time of assembly and no attempt should be made to lubricate it. Put a small amount of grease in the pilot bushing.
- Install the driven disc with the short end of the hub toward the flywheel. Use a spare transmission mainshaft or an aligning arbor to align the pressure plate assembly and the driven disc.
- Leave the arbor in place while tightening the pressure plate bolts evenly a turn or two at a time. Tighten the bolts to 25 ft. lbs. (34 Nm).
- Install the flywheel housing. Tighten the bolts to 40-50 ft. lbs. (54-68 Nm).
- Install the transmission and transfer case.
See Figures 17 and 18
- Remove the transmission and transfer case.
- Remove the clutch throwout bearing and pedal return spring from the clutch fork.
- Remove the flywheel housing from the engine.
- Disconnect the clutch form from the ball stud by forcing it toward the center of the vehicle.
- Matchmark the clutch cover to the flywheel with a center punch so that the cover an later be installed in the same position on the flywheel. This is necessary to maintain engine balance.
- Loosen the clutch attaching bolts alternately, one turn at a time to avoid distorting the clutch cover flange, until the diaphragm spring tension is released.
- Support the pressure plate and cover assembly while removing the last of the bolts; remove the pressure plate and driven disc from the flywheel.
- If it is necessary to disassemble the pressure plate assembly, note the position of the grooves on the edge of the pressure plate and cover. These marks must be aligned during assembly to maintain balance. The clutch diaphragm spring and two pivot rings are riveted to the clutch cover. Inspect the spring, rings and cover for excessive wear or damage. If there is a defect, replace the complete cover assembly.
Replace the clutch assembly in reverse order of the removal procedure, taking note of the following:
- Use extreme care at all times not to get the clutch driven disc dirty in any way.
- Lightly lubricate the inside of the clutch driven disc's spline with a coat of wheel bearing grease. Do the same to the input shaft of the transmission. Wipe off all excess grease so that none will fly off and get onto the driven disc.
- Lubricate the throwout bearing collar, the ball stud and the clutch fork with wheel bearing grease.
- Use a pilot shaft or a spare transmission main shaft to align the driven shaft and the clutch pressure plate when attaching the assembly to the flywheel.
- Tighten down on the clutch-to-flywheel attaching bolts alternately so that the clutch is drawn squarely into position on the flywheel. Each bolt must be tightened one turn at a time to avoid bending the clutch cover flange. Tighten the bolts to 30-40 ft. lbs. (41-54 Nm).