Liberty, Wrangler, 1997-2005

Driven Disc & Pressure Plate

Print

Removal & Installation



  1. Remove transmission.
  2.  
  3. If original clutch cover will be reinstalled, mark position of cover on flywheel for assembly reference. Use paint or a scriber for this purpose.
  4.  
  5. If clutch cover is to be replaced, cover bolts can be removed in any sequence. However, if original cover will be reinstalled, loosen cover bolts evenly and in rotation to relieve spring tension equally. This is necessary to avoid warping cover.
  6.  
  7. Remove cover bolts and remove cover and disc.

    Click image to see an enlarged view

    Fig. Clutch disc and pressure plate inspection

  8.  

To install:

  1. Lightly scuff sand flywheel face with 180 grit emery cloth. Then clean surface with a wax and grease remover.
  2.  
  3. Lubricate pilot bearing with Mopar®high temperature bearing grease.
  4.  
  5. Check runout and free operation of new clutch disc as follows:
  6.  
  7. Slide disc onto transmission input shaft splines. Disc should slide freely on splines.
  8.  
  9. Leave disc on shaft and check face runout with dial indicator. Check runout at disc hub and about 6 mm ( 1 / 4 in.) from outer edge of facing.
  10.  
  11. Face runout should not exceed 0.020 in. (0.5 mm) Obtain another clutch disc if runout exceeds this limit.
  12.  
  13. Position clutch disc on flywheel. Be sure side of disc marked flywheel side is positioned against flywheel. If disc is not marked, be sure flat side of disc hub is toward flywheel.
  14.  
  15. Inspect condition of pressure plate surface of clutch cover. Replace cover if this surface is worn, heat checked, cracked, or scored.
  16.  
  17. Insert clutch alignment tool in clutch disc.
  18.  
  19. Insert alignment tool in pilot bearing and position disc on flywheel. Be sure disc hub is positioned correctly. Side of hub marked Flywheel Side should face flywheel. If disc is not marked, place flat side of disc against flywheel.
  20.  
  21. Position clutch cover over disc and on flywheel.
  22.  
  23. Install clutch cover bolts finger tight.
  24.  
  25. Tighten cover bolts evenly and in rotation a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. Tightening torques are 23 ft. lbs. (31 Nm) on 2.5L engines and 38 ft. lbs. (52 Nm) on 4.0 L engines.

    Start all 6 bolts by hand.
     
    Tighten 3 pilot hole bolts 3 / 2 of the way (any sequence)
     
    Starting 180 degrees from the last pilot bolt, tighten 3 large hole bolts three quarters of the way (any sequence)
     
    Tighten 3 pilot hole bolts all the way (any sequence)
     
    Starting 180 degrees from last pilot bolt, tighten 3 large bolts all the way (any sequence)
     

  26.  
  27. Apply light coat of Mopar® high temperature bearing grease to clutch disc hub and splines of transmission input shaft. Do not over lubricate shaft splines. This will result in grease contamination of disc.
  28.  
  29. Install transmission.
  30.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transfer case, if equipped
     
    Transmission
     
    Pressure plate. Loosen the bolts evenly in 1 / 2 turn steps.
     
    Clutch disc
     

  4.  

To install:

  1. Install or connect the following:

    Clutch disc and pressure plate. Tighten the pressure plate bolts evenly in 1 / 2 turns to 23 ft. lbs. (31 Nm) for 2.4L and 2.5L engines; 37 ft. lbs. (50 Nm) for 4.0L engines.
     
    Transmission
     
    Transfer case, if equipped
     
    Negative battery cable
     

  2.  

2.4L & 3.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the transmission.
  4.  
  5. Mark position of pressure plate on flywheel with paint or a scriber for assembly reference, if clutch is not being replaced.
  6.  
  7. Loosen pressure plate bolts evenly and in rotation to relieve spring tension and avoid warping the plate.
  8.  
  9. Remove pressure plate bolts and pressure plate and disc.
  10.  

To install:

  1. Lightly scuff sand flywheel face with 180 grit emery cloth, then clean with a wax and grease remover.
  2.  
  3. Lubricate pilot bearing with Mopar®high temperature bearing grease or equivalent.
  4.  
  5. Check runout and operation of a new clutch disc.
    NOTE
    Disc must slide freely on transmission input shaft splines.

  6.  
  7. With the disc on the input shaft, check face runout with dial indicator. Check runout at disc hub 1 / 4 inches (6 mm.) from outer edge of facing. Obtain another clutch disc if runout exceed 0.020 in.(0.5 mm).
  8.  
  9. Position clutch disc on flywheel with side marked flywheel against the flywheel.
    NOTE
    If not marked, the flat side of disc hub goes towards the flywheel on the 3.7L engine and towards the transmission on 2.4L engine.

  10.  
  11. Insert clutch alignment tool through the clutch disc and into the pilot bearing.
  12.  
  13. Position clutch pressure plate over disc and on the flywheel.
  14.  
  15. Install pressure plate bolts finger tight.
    WARNING
    Use only the factory bolts to mount the pressure plate. The bolts must be the correct size. If bolts are too short, there isn-t enough thread engagement, if too long bolts interfere with the Dual Mass Flywheel.

  16.  
  17. Tighten pressure plate bolts evenly and in rotation a few threads at a time.
    WARNING
    The bolts must be tightened evenly and to specified torque. Failure to follow these instructions will distort the pressure plate.

  18.  
  19. Tighten pressure plate bolts to 23 ft. lbs. (31 Nm) on 2.4L engines and 37ft. lbs. (50 Nm) on 3.7L engines.
  20.  
  21. Apply light coat of Mopar®high temperature bearing grease or equivalent to clutch disc hub and splines of transmission input shaft.
    NOTE
    Do not over lubricate shaft splines. This will result in grease contamination of disc.

  22.  
  23. Install the transmission.
  24.  

2.8L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove transmission.
  4.  
  5. Mark position of pressure plate on flywheel with paint or a scriber for assembly reference, if clutch is not being replaced.
  6.  
  7. Loosen pressure plate bolts evenly and in rotation to relieve spring tension and avoid warping the plate.
  8.  
  9. Remove pressure plate bolts and pressure plate and disc.
  10.  

To install:

  1. Lightly scuff sand flywheel face with 180 grit emery cloth, then clean with a wax and grease remover.
  2.  
  3. Lubricate pilot bearing with Mopar®high temperature bearing grease or equivalent.
  4.  
  5. Check runout and operation of the new clutch disc.
    NOTE
    Disc must slide freely on transmission input shaft splines.

  6.  
  7. With the disc on the input shaft, check face runout with dial indicator. Check runout at disc hub 1 / 4 inches (6 mm.) from outer edge of facing. Obtain another clutch disc if runout exceed 0.020 in.(0.5 mm).
  8.  
  9. Position clutch disc on flywheel with side marked flywheel side against the flywheel. If not marked, the flat side of disc hub goes towards the flywheel.
  10.  
  11. Insert clutch alignment tool through the clutch disc and into the pilot bearing.
  12.  
  13. Position clutch pressure plate over disc and on the flywheel.
  14.  
  15. Install pressure plate bolts finger tight.
  16.  
  17. Tighten pressure plate bolts evenly and in rotation a few threads at a time.
    WARNING
    The bolts must be tightened evenly and to specified torque. Failure to follow these instructions will distort the pressure plate.

  18.  
  19. Tighten pressure plate bolts to 40 ft. lbs. (54 Nm).
  20.  
  21. Apply light coat of Mopar® high temperature bearing grease, or equivalent, to clutch disc hub and splines of transmission input shaft.
    NOTE
    Do not over lubricate shaft splines. Failure to follow these instructions will result in contamination of disc.

  22.  
  23. Install the transmission.
  24.  

 
label.common.footer.alt.autozoneLogo