Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

Clutch Disc and Pressure Plate Assembly

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REMOVAL & INSTALLATION FC Series



  1. Remove the transmission and transfer case from the vehicle.
  2.  
  3. On the FC-150, remove the flywheel housing. On the FC-170, remove the flywheel housing pan.
  4.  
  5. Mark the clutch pressure plate and engine flywheel with a center punch so that the clutch assembly can be reinstalled in the same position after adjustments or replacement are completed.
  6.  
  7. Remove the clutch pressure plate bracket bolts equally, a little at a time, to prevent distortion and to relieve the clutch springs evenly.
  8.  
  9. Remove the pressure plate assembly and clutch disc from the flywheel. Before the clutch is reinstalled, it should be inspected for warpage. If grease or oil is evident on the disc friction facings, the facings should be replaced and the cause of the oil accumulation corrected.
  10.  
  11. Put a small amount of cup grease in the flywheel pilot bushing and install the clutch disc with the short end of the hub toward the flywheel. Next, place the pressure plate assembly in position.
  12.  
  13. With a clutch disc aligning arbor or a spare transmission mainshaft, align the clutch disc splines leaving the arbor in position while tightening the pressure plate screws evenly. Torque the bolts to 17 ft. lb.
  14.  
  15. Assemble the flywheel housing to the engine, or flywheel housing pan, and install the transmission and transfer case. Make sure that the clutch release bearing carrier return spring is hooked in place.
  16.  
  17. Assemble the rest of the components in the reverse order of removal. Adjust the clutch control cable so that there is 1 / 2 in. of free pedal travel.
  18.  

1966-70 Jeepster/Commando

4-134 ENGINES
  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 that the clutch assembly can be reinstalled in the same position after adjustments or replacement are completed.
  6.  
  7. Remove the clutch pressure plate bracket bolts equally, a little at a time, to prevent distortion and to relieve the clutch springs evenly.
  8.  
  9. Remove the pressure plate assembly and clutch disc from the flywheel. Before the clutch is reinstalled, it should be inspected for warpage. If grease or oil is evident on the disc friction facings, the facings should be replaced and the cause of the oil accumulation corrected.
  10.  
  11. Put a small amount of cup grease in the flywheel pilot bushing and install the clutch disc with the short end of the hub toward the flywheel. Next, place the pressure plate assembly in position.
  12.  
  13. With a clutch disc aligning arbor or a spare transmission mainshaft, align the clutch disc splines leaving the arbor in position while tightening the pressure plate screws evenly. Torque the bolts to 17 ft. lb.
  14.  
  15. Assemble the flywheel housing to the engine and reinstall the transmission and transfer case. Make sure that the clutch release bearing carrier return spring is hooked in place.
  16.  
  17. Assemble the rest of the components in the reverse order of removal. Adjust the clutch control cable so that there is 1 in. of free pedal travel.
  18.  

6-225 ENGINES

See Figure 1

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Fig. Fig. 1: Cross-sectional view of the GM diaphragm clutch assembly

  1. Remove the transmission.
  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 fork 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 can later be installed in the same position on the flywheel.
  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 bolts.
  14.  
  15. Remove the pressure plate and clutch disc from the flywheel.
  16.  

Use extreme care to keep the clutch disc clean.

  1. Before installing the clutch, lubricate the inner surface of the pilot bushing in the crankshaft; the splines of the transmission drive gear shaft, sliding the clutch disc over the shaft and wiping off excess lubricant; the front bearing retainer of the transmission, sliding the throwout bearing along the retainer several times and removing any excess grease; the groove in the throwout bearing collar; and the ball stud in the flywheel housing together with the seat in the clutch fork.
  2.  

Use wheel bearing grease sparingly to lubricate all of the above. If excessive grease is applied, operating heat will cause it to run out onto the clutch disc, ruining it.

  1. Install and reassemble the clutch in the reverse order of removal, taking note of the following:
    1. Be certain that the mark on the clutch cover is aligned with the mark made on the flywheel during clutch removal.
    2.  
    3. Tighten the clutch attaching bolts alternately, so that the clutch is drawn into position squarely on the flywheel. Turn each bolt one turn at a time to avoid bending the clutch cover flange. Tighten the attaching bolts to 30-40 ft. lb.
    4.  
    5. Be certain the dowel pins on the flywheel housing are installed in the cylinder block when the housing is installed.
    6.  

  2.  

1962-65 Wagoneer and J-Series Truck

These vehicles use a hydraulically actuated clutch.

  1. Remove the transmission and transfer case.
  2.  
  3. Remove the inspection cover from the flywheel housing.
  4.  
  5. Mark the clutch plate and flywheel for installation.
  6.  
  7. Remove four pressure plate bolts, leaving two opposed bolts for last.
  8.  
  9. Remove the remaining two bolts evenly, a little at a time, to avoid distortion.
  10.  
  11. Installation is the reverse of removal. Use a clutch aligning tool for ease of installation. Torque the pressure plate bolts evenly and in a cross pattern to 32 ft. lb.
  12.  

1966-70 Wagoneer and J-Series Truck

8-350 ENGINES

Remove and install the clutch in the same manner as outlined for the 1966-70 Jeepster/Commando with the 6-225, above.

1966-70 Wagoneer and J-Series Truck

6-232 and 8-327 ENGINES

Remove and install the clutch in the same manner as outlined for the 1966-70 Jeepster/Commando with the 4-134, above.

1971-73 Jeepster/Commando and 1971-83 Wagoneer & Cherokee and 1971-83 J-Series Truck See Figures 2 through 18

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Fig. Fig. 2: Clutch components used on the Wagoneer, Cherokee and J-series truck models



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Fig. Fig. 3: Typical clutch alignment tool, note how the splines match the transmission's input shaft



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Fig. Fig. 4: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 5: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 6: Check across the flywheel surface, it should be flat



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Fig. Fig. 7: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 8: ... then remove the flywheel from the crankshaft in order to replace it or have it machined



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Fig. Fig. 9: Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts



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Fig. Fig. 10: Check the pressure plate for excessive wear



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Fig. Fig. 11: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 12: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 13: Clutch plate installed with the arbor in place



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



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Fig. Fig. 15: Pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 16: You may want to use a thread locking compound on the clutch assembly bolts



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Fig. Fig. 17: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 18: Be sure to use a torque wrench to tighten all bolts

  1. Remove the transmission.
  2.  
  3. Remove the starter, throwout bearing and sleeve assembly and clutch housing.
  4.  
  5. Mark the clutch cover, pressure plate and flywheel with a center punch to insure correct alignment during assembly.
  6.  
  7. Loosen the attaching screws in sequence, one or two turns at a time until the spring tension on the cover is released. This is to prevent the clutch cover from becoming warped, which could result in clutch chatter when reinstalled.
  8.  
  9. Install the clutch in the reverse order of removal, tighten the attaching bolts of the cover in sequence, one or two turns at a time to 40 ft. lb.
  10.  

1984-83 Wagoneer, Cherokee, Comanche

These vehicles use a hydraulic clutch.

  1. Remove the transmission or transmission/transfer case assembly.
  2.  
  3. Matchmark the pressure plate and flywheel. Loosen the pressure plate bolts, a little at a time, in rotation, to avoid warpage.
  4.  
  5. Remove the pressure plate and clutch disc.
  6.  
  7. Remove the pilot bushing wick from the bushing bore. Soak the wick in clean engine oil.
  8.  
  9. Installation is the reverse of removal. A clutch aligning tool, either store-bought, or made from an old transmission input shaft, must be used to align the clutch properly for installation. The pressure plate bolts must be tightened a little at a time, in rotation, to avoid warpage.
  10.  

PEDAL HEIGHT, FREE-PLAY AND LINKAGE ADJUSTMENTSFC Series



  1. Loosen the locknut at the clutch control cable clevis.
  2.  
  3. Remove the clevis pin.
  4.  
  5. Turn the clevis until the free-play, measured at the clutch pedal pad, is 1 / 2 inch.
  6.  
  7. Install the pin and tighten the locknut.
  8.  

1966-70 Jeepster/Commando See Figures 19 and 20

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Fig. Fig. 19: Clutch linkage adjustment 1966-70 Commando models with cross-shaft tube and lever type linkage



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Fig. Fig. 20: Clutch linkage adjustment 1966-70 Commando models with control cable type linkage

There are two types of clutch linkage used on 1966-70 Jeepster/Commandos: the cross-shaft tube and lever type and the clutch control cable type. Both use a cable to actuate the release and engagement of the clutch.

To adjust the cross-shaft lever and tube type linkage:

  1. With the clutch cross-shaft tube and lever assembly positioned at a 52º angle for the 4-134 engine and a 58º angle for the 6-225 engine, adjust the clutch control cable assembly from the clutch pedal to the cross-shaft lever, making sure that the clutch pedal is against the pedal support bracket stop.
  2.  
  3. With the cross-shaft assembly positioned as above, push the clutch housing release lever rearward, until the clutch throwout bearing contacts the clutch pressure plate release levers or diaphragm plate.
  4.  
  5. Adjust the clutch fork cable from the release lever to the clutch cross-shaft lever, until the cable clevis just enters the lever hold.
  6.  
  7. Remove the clevis pin and lengthen the cable 2 1 / 2 turns of the clevis for the 6-225 engine and 3 turns for the 4-134 engine, to obtain about 3 / 4 in. of free-play.
  8.  
  9. Release the clutch lever and insert the cable clevis pin and lock the clevis jam nut.
  10.  

To adjust the clutch control cable type linkage:
  1. With the clutch pedal against the pedal support bracket stop, adjust the ball adjusting nut until the slack is removed from the cable and the clutch throwout bearing contacts the clutch pressure plate, release levers or diaphragm plate.
  2.  
  3. Loosen the ball adjusting nut 2 1 / 2 turns to obtain about 1 / 4 in. of free-play.
  4.  
  5. Lock the hex nut.
  6.  

1962-65 Wagoneer and Truck See Figure 21

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Fig. Fig. 21: Clutch linkage adjustment 1962 65 Wagoneer and J-series truck models

Clutch bearing free-play should be .050 in. This is determined by the location of the piston in the slave cylinder. The adjusting yoke on the slave cylinder is set in the following manner:

  1. Unhook the clutch fork return spring and push the slave cylinder pushrod in to hold the piston in its fully retracted position in the cylinder bore.
  2.  
  3. Hold this position while moving the clutch lever until the clutch release bearing touches the clutch fingers.
  4.  
  5. Adjust the pushrod locknut until the connecting pin enters the clutch lever, then back off the locknut 1 1 / 2 to 2 turns.
  6.  
  7. Connect the return spring. The clutch release bearing free-play should now be 0.050-0.060 in.
  8.  

1966-69 Wagoneer and J-Series Truck See Figure 22

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Fig. Fig. 22: Clutch linkage adjustment 1966 70 Wagoneer and Truck models

  1. Disconnect the adjustable rod from the clutch pedal.
  2.  
  3. Adjust the clutch pedal stop bolt for a positive overcenter position. This is done by turning the bolt in or out of the crossmember to obtain 1 / 4 - 1 / 2 in. of clutch pedal travel before the overcenter spring assists the pedal to the floorboard. The pedal may be 3 / 8 - 5 / 8 in. higher than the pad on the brake pedal. This is a normal condition.
  4.  
  5. With the clutch pedal resting against the stop bolt, adjust the length of the adjustable rod by turning the ball joint in or out on the rod, so that when the adjustable rod is connected the arm of the clutch pedal cross-shaft is at a 30º angle with a 8-350 and 49º with a 6-232 or 8-327, in relation to the top of the left frame side rail.
  6.  
  7. To adjust clutch pedal free-play, adjust the cross-shaft-to-throwout lever link, so that the clutch pedal can be depressed 1 in. before the clutch starts to disengage.
  8.  

There is a special tool available for setting the angle of the arm of the clutch pedal cross-shaft as outlined in Step 3 of the above procedure. Tool W-341 is for the vehicle equipped with a 8-350 and gives the 30º angle and tool W-317 is for the vehicle equipped with a 6-232 or 8-327 and gives the 49º angle.

1971-72 Jeepster/Commando, Wagoneer and J-Series Truck See Figures 23, 24 and 25

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Fig. Fig. 23: Exploded view of the clutch linkage 1971 72 Commando models



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Fig. Fig. 24: Clutch pedal height adjustment 1971 72 models



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Fig. Fig. 25: Clutch pedal height adjustment 1971 72 Wagoneer and Truck models

  1. The clutch pedal has an adjustable stop located on the pedal support bracket, directly behind the instrument cluster. Adjust the stop to provide 8 3 / 8 in. on the Wagoneer and truck, and 8 in. on the Jeepster/Commando, between the top of the pedal pad and the closest point, 90º on the bare floor pan.
  2.  
  3. Lift the clutch pedal up against the pedal support bracket stop.
  4.  
  5. Unhook the clutch fork return spring.
  6.  
  7. Loosen the ball adjusting nut until some cable slack exists.
  8.  
  9. Adjust the ball adjusting nut until the slack is removed from the cable and the clutch throwout bearing contacts the pressure fingers.
  10.  
  11. Back off the ball adjusting nut 3 / 4 turn to provide freeplay.
  12.  
  13. Tighten the jam nut.
  14.  
  15. Hook the clutch fork return spring.
  16.  

1973-74 Jeepster/Commando, Wagoneer, Cherokee, and J-Series Truck See Figure 26

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Fig. Fig. 26: Exploded view of the clutch linkage and its components 1973 Commando models

  1. Adjust the bellcrank outer support bracket to provide approximately 1 / 8 in. bellcrank end-play.
  2.  
  3. Lift the clutch pedal up against the pedal stop.
  4.  
  5. On the clutch pushrod (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. For the Commando, the free-play should be 3 / 4 - 1 / 2 in.; for the Wagoneer, Truck and Cherokee, the free-play should be 5 / 8 - 3 / 8 in.
  8.  

1975-83 Wagoneer and Cherokee

1975-83 J-Series Truck

See Figure 27

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Fig. Fig. 27: Exploded view of the clutch linkage 1973 83 Cherokee and J-series truck models

  1. Lift the pedal up against the pedal stop.
  2.  
  3. Adjust the clutch pushrod lower ball pivot assembly in or out to position the bellcrank inner lever parallel to the front face of the clutch housing. Proper positioning should be slightly forward from vertical.
  4.  
  5. Loosen the jam nut and turn the throwout fork adjuster in or out to obtain 3 / 8 to 5 / 8 in. free-play. Tighten the jam nut.
  6.  

 
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