Jeep CJ/Scrambler 1971-1986 Repair Guide

Pressure Plate and Driven Disc

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REMOVAL & INSTALLATION



See Figures 1 through 27

4-134

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the transmission and transfer case from the vehicle.
  2.  
  3. Remove the flywheel housing.
  4.  
  5. Mark the clutch pressure plate and engine flywheel with a center punch so the clutch assembly may be installed in the same position after adjustments or replacement are complete.
  6.  
  7. Loosen the clutch pressure plate bracket bolts equally, a little at a time, to prevent distortion and relieve the clutch springs evenly. Remove the bolts.
  8.  
  9. Remove the pressure plate assembly (bracket and pressure plate) and driven plate from the flywheel. The driven plate 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 down and cause injury.
  10.  
  11. 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.
  12.  
  13. Install the driven plate 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 plate.
  14.  
  15. Leave the arbor in place while tightening the pressure plate screws evenly a turn or two at a time. Torque the bolts to 25 ft. lbs.
  16.  
  17. Install the flywheel housing. Torque the bolts to 40-50 ft. lbs.
  18.  
  19. Install the transmission and transfer case.
  20.  

6-225

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the transmission and transfer case.
  2.  
  3. Remove the clutch throwout bearing and pedal return spring from the clutch fork.
  4.  
  5. Remove the flywheel housing from the engine.
  6.  
  7. Disconnect the clutch form from the ball stud by forcing it toward the center of the vehicle.
  8.  
  9. Mark the clutch cover and 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.
  10.  
  11. Loosen the clutch attaching bolts alternately, one turn at a time to avoid distorting the clutch cover flange, until the diaphragm spring is released.
  12.  
  13. Support the pressure plate and cover assembly while removing the last of the bolts; remove the pressure plate and driven plate from the flywheel.
  14.  
  15. 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.
  16.  
  17. Replace the clutch assembly in reverse order of the removal procedure, taking note of the following:
    1. Use extreme care at all times not to get the clutch driven plate dirty in any way.
    2.  
    3. Lightly lubricate the inside of the clutch driven plate'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 plate.
    4.  
    5. Lubricate the throwout bearing collar, the ball stud and the clutch fork with wheel bearing grease.
    6.  
    7. 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.
    8.  
    9. 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. Torque the bolts to 30-40 ft. lbs.
    10.  

  18.  

1972-86 except 4-151

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the transmission.
  2.  
  3. Remove the starter.
  4.  
  5. Remove the throwout bearing and sleeve assembly.
  6.  
  7. Remove the bell housing.
  8.  
  9. Mark the clutch cover, pressure plate and the flywheel with a center punch so that these parts can be later installed in the same position.
  10.  
  11. Remove the clutch cover-to-flywheel attaching bolts. When removing these bolts, loosen them in rotation, one or two turns at a time, until the spring tension is released. The clutch cover is a steel stamping which could be warped by improper removal procedures, resulting in clutch chatter when reused.
  12.  
  13. Remove the clutch assembly from the flywheel.
  14.  
  15. 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.
  16.  
  17. Install the driven plate 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 plate.
  18.  
  19. Leave the arbor in place while tightening the pressure plate screws evenly a turn or two at a time. Torque the bolts to 40 ft. lbs.
  20.  
  21. Install the bell housing. Torque the bolts to 40 ft. lbs.
  22.  
  23. Install the throwout bearing and sleeve assembly.
  24.  
  25. Install the starter.
  26.  
  27. Install the transmission.
  28.  

4-151

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the shift lever boot.
  2.  
  3. Remove the shift lever assembly.
  4.  
  5. Raise the vehicle and support it on jackstands.
  6.  
  7. Remove the transmission and transfer case.
  8.  
  9. Remove the slave cylinder-to-clutch housing bolts.
  10.  
  11. Disengage the slave cylinder pushrod from the throwout lever and move the cylinder out of the way.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the throwout bearing.
  16.  
  17. Unbolt and remove the clutch housing.
  18.  
  19. Mark the position of the clutch pressure plate and remove the pressure plate bolts evenly, a little at a time in rotation.
  20.  
  21. Remove the pilot bushing lubricating wick from its bore in the crankshaft and soak the wick in clean engine oil.
  22.  
  23. The clutch release bearing (throwout bearing) is lubricated at time of assembly and no attempt should be made to lubricate it.
  24.  
  25. Install the driven plate 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 plate.
  26.  
  27. Leave the arbor in place while tightening the pressure plate screws evenly a turn or two at a time. Torque the pressure plate bolts to 23 ft. lbs.
  28.  
  29. Install the pilot bushing lubricating wick in its bore in the crankshaft.
  30.  
  31. Install the clutch housing. Torque the clutch housing to 54 ft. lbs.
  32.  
  33. Install the throwout bearing.
  34.  
  35. Install the starter.
  36.  
  37. Engage the slave cylinder pushrod in the throwout lever.
  38.  
  39. Install the slave cylinder-to-clutch housing bolts.
  40.  
  41. Install the transmission and transfer case. Torque the transmission-to-clutch housing bolts to 54 ft. lbs.; the transfer case-to-transmission bolts to 30 ft. lbs.
  42.  
  43. Lower the vehicle.
  44.  
  45. Install the shift lever assembly.
  46.  
  47. Install the shift lever boot.
  48.  



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Fig. Fig. 1: View of the clutch alignment arbor, used to install the clutch and pressure plate assembly



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Fig. Fig. 2: View of the clutch and pressure plate assembly



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Fig. Fig. 3: Removing the clutch and pressure plate bolts



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Fig. Fig. 4: Removing the clutch and pressure plate assembly



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Fig. Fig. 5: Removing the clutch and pressure plate



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Fig. Fig. 6: View of the flywheel once the clutch assembly is removed



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Fig. Fig. 7: Removing the flywheel bolts. Be sure to lock the flywheel in place



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Fig. Fig. 8: Removing the flywheel from the crankshaft



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Fig. Fig. 9: Add a thread locking agent to the flywheel bolts upon installation



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Fig. Fig. 10: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 11: Check across the flywheel surface, it should be flat



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Fig. Fig. 12: Checking the pressure plate for excessive wear



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Fig. Fig. 13: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 14: Clutch plate installed with the arbor in place



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Fig. Fig. 15: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 16: Pressure plate-to-flywheel bolt hole should align



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Fig. Fig. 17: Install locking agent to clutch assembly bolts



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Fig. Fig. 18: Install the clutch assembly bolts and tighten in steps, in an X pattern



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Fig. Fig. 19: Be sure to use an torque wrench to tighten all bolts



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Fig. Fig. 20: Grease the clutch release fork ball



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Fig. Fig. 21: View of the clutch release fork, check this for signs of damage



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Fig. Fig. 22: View of the clutch release fork bearing clips, make sure these are not bent or broken



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Fig. Fig. 23: Removing the clutch release fork bearing clips



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Fig. Fig. 24: Grease the throwout bearing assembly at the outer contact points



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Fig. Fig. 25: Grease the throwout bearing assembly at the inner contact points



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Fig. Fig. 26: Installing the clutch release fork bearing clip



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Fig. Fig. 27: View of the clutch release fork assembly installed, be sure all parts move freely

CLUTCH LINKAGE ADJUSTMENT



See Figures 28, 29, 30 and 31

1971

As the clutch facings wear out the free travel of the clutch pedal diminishes. When sufficient wear occurs, the pedal clearance must be adjusted to 1-1 1 / 2 in. (25-38mm). The free pedal clearance is adjusted by lengthening or shortening the clutch fork cable.

To make this adjustment, loosen the jam nut on the cable clevis and lengthen or shorten the cable to obtain the proper clearance at the pedal pad, then tighten the jam nut.

PEDAL HEIGHT ADJUSTMENT



1972 Only

The clutch pedal has an adjustable stop located on the pedal support bracket directly behind the instrument cluster.

Adjust the stop to provide the specified clearance between the top of the pedal pad and the closest point on the bar floor pan. The distance must be 8 in.



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Fig. Fig. 28: Clutch pedal height adjustment for 1972 models



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Fig. Fig. 29: Clutch linkage components 1976-83 models except with the 4-151 engine

CONTROL CABLE ADJUSTMENT



1972
  1. Lift up the clutch pedal against the pedal support bracket stop.
  2.  
  3. Unhook the clutch fork return spring.
  4.  
  5. Loosen the ball adjusting nut until some cable slack exists.
  6.  
  7. Adjust the ball adjusting nut until the slack is removed from the cable and the clutch throwout bearing contacts the pressure plate fingers.
  8.  
  9. Back off the ball adjusting nut 3 / 4 of a turn to provide the proper amount of free play. Tighten the jam nut.
  10.  
  11. Hook the clutch fork return spring.
  12.  



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Fig. Fig. 30: Clutch linkage used on 1972 models



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Fig. Fig. 31: Clutch linkage used on 1973-75 models

1973-75
  1. Adjust the bellcrank outer support bracket to provide approximately 1 / 8 in. (3mm) of bellcrank end play.
  2.  
  3. Lift up the clutch pedal against the pedal stop.
  4.  
  5. On the clutch push rod (pedal to bellcrank) adjust the lower ball pivot assembly onto or off the rod (as required) to position the bellcrank inner lever parallel to the front face of the clutch housing (slightly forward from vertical).
  6.  
  7. Adjust the clutch fork release rod (bellcrank to release fork) to obtain the maximum specified clutch pedal free play of 3 / 4 in. (19mm) on 1973-74 models and 1 in. (25mm) on 1975 models.
  8.  

1976-83

4-151 and all 1984 and later models have a non-adjustable hydraulic clutch.

  1. Lift the pedal up against the stop.
  2.  
  3. Loosen the release rod adjuster jam nut, under the vehicle.
  4.  
  5. Adjust the pedal free-play to about one inch.
  6.  
  7. Tighten the jam nut.
  8.  

 
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