Jeep Wrangler/YJ 1987-1995 Repair Guide

Pressure Plate and Driven Disc

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REMOVAL & INSTALLATION



See Figures 1 through 14



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Fig. Fig. 1: Clutch components-2.5L engine-1987-93



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Fig. Fig. 2: Clutch components-4.2L engine-1987-93



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Fig. Fig. 3: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 4: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 5: Check across the flywheel surface, it should be flat



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Fig. Fig. 6: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 7: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 8: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts



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Fig. Fig. 9: Pilot bearing installation



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Fig. Fig. 10: Tap gently to install the pilot bearing



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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: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 14: Be sure to use a torque wrench to tighten all bolts


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. Raise and safely support the vehicle.
  2.  
  3. Remove the transmission or transmission/transfer case assembly.
  4.  
  5. Matchmark the pressure plate and flywheel. Loosen the pressure plate bolts, a little at a time, in rotation, to avoid warpage.
  6.  
  7. Remove the pressure plate and clutch disc.
  8.  
  9. Inspect the flywheel for scoring, cracks, warpage or other wear; resurface or replace as necessary.
  10.  
  11. Inspect the pilot bearing for excessive wear or damage and replace as necessary.
  12.  

To install:
  1. If removed, install the pilot bearing after lubricating with grease. Seat the bearing in the crankshaft with a clutch alignment tool.
  2.  
  3. Check the clutch disc run- out by installing the disc on the transmission input shaft. Run-out should not exceed 0.020 in. (0.5mm) when measured 1 / 4 inch from the outer edge of the facing.
  4.  
  5. Install the clutch alignment tool in the pilot bearing.
  6.  
  7. Install the clutch disc on the tool.
  8.  
  9. Install the pressure plate and tighten the bolts finger-tight. The pressure plate bolts must be tightened a little at a time, in rotation, to avoid warpage. Torque the pressure plate bolts as follows:

    2.5L engine-23 ft. lbs. (31 Nm)
     
    4.0L and 4.2L engines-40 ft. lbs. (54 Nm)
     

  10.  
  11. Install the transmission or transmission/transfer case assembly and lower the vehicle.
  12.  

 
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