REMOVAL & INSTALLATION
See Figures 1 through 13
- Disconnect the negative battery cable for safety.
- Remove the transmission from the vehicle.
- Hold the flywheel from turning using a large prytool or a special flywheel holding tool which locks the flywheel teeth. With the flywheel held stationary, loosen and remove the pressure plate mounting bolts.
- Remove the pressure plate and the clutch disc from the flywheel.
- Inspect the flywheel for wear and/or scoring and machine or replace, as necessary. Check the flywheel for excessive runout using a dial indicator; if runout exceeds 0.0078 in. (0.2mm) the flywheel should be machined or replaced.
- Inspect the clutch disc and pressure plate for wear or damage. Check the depth of the rivet heads on the clutch disc. Standard depth is 0.05 in (1.2mm) for the Samurai or 0.06 in. (1.6mm) for other models. The wear limit is 0.02 in. (0.5mm) for all models. Any clutch disc showing wear equal to or greater than the wear limit should be replaced.
- Check the clutch disc, pressure plate and flywheel for light burnt or glazed surfaces. A glazed component will have a glass-like surface. If found, break the glass-like finish of light glazing using 120-200 grit sandpaper.
- Clean and inspect the clutch release bearing and the input shaft. Many of the late-model trucks covered by this guide utilize a sealed release bearing. DO NOT submerge a sealed bearing in or soak it with solvent.
The clutch release bearing is a relatively inexpensive part, that performs a very important function. ALWAYS replace the bearing when a new disc and pressure plate is installed. For that matter, it is not a bad idea to replace it even when other components are being reused.
- Make sure that the pressure plate retaining bolts and the bolt holes in the flywheel are clean and free of grease or oil to assure proper fastening during installation.
- Apply a high temperature lithium grease to the thrust surfaces on the throwout bearing and input shaft. Be careful not to apply too much grease which could come off and contaminate the surfaces of the clutch disc.
- Make sure the clutch disc, pressure plate and flywheel surfaces are clean and free of all grease, oil or other possible contaminants.
- Using a clutch alignment arbor (preferably the exact one with the proper sized pilot and proper splines), position and hold the clutch disc against the flywheel.
There are several inexpensive clutch alignment tools on the market. One company even makes small plastic replicas of the input shaft. These plastic alignment tools are well designed and work perfectly for most applications.
- Install the pressure plate over the disc, flywheel and alignment arbor assembly, then carefully finger-tighten the bolts.
- Check to make sure that the clutch disc is properly aligned to the pressure plate and flywheel. To do this, first look down the length of the alignment arbor and make sure it seems perfectly straight. Next, grasp the end of the arbor and withdraw it gently (note the pressure plate bolts must have been tightened sufficiently to hold the clutch plate at this stage or it will fall out of alignment the second that the arbor is removed). If the clutch disc is properly aligned, the arbor will slide smoothly out from the flywheel pilot and the clutch splines. The arbor should also insert back into both without any hesitation.
- Once you are satisfied that the disc is properly aligned, tighten the pressure plate bolts and evenly using multiple passes of a star pattern until all are tightened to 159-248 inch lbs. (18-28 Nm).
- Remove the clutch disc alignment tool.
- Install the transmission.
- Check and adjust the clutch, as necessary.
- Connect the negative battery cable.
Clutch Pedal Height
See Figures 14, 15 and 16
The clutch pedal height should not be a periodic adjustment, but may be checked from time-to-time. More importantly, it should be checked after components of the mechanical clutch system have been replaced.
The proper height varies slightly from model-to-model:
If adjustment is necessary, loosen the locknut and turn the adjusting bolt until the appropriate height is reached. Once set, keep the bolt from turning and tighten the locknut to secure the adjustment.Clutch Pedal Free-Play
See Figures 17, 18, 19 and 20
Unlike pedal height, which should not change because of wear, the clutch pedal free-play will tend to change as the clutch disc wears. The pedal free-play should therefore be checked from time-to-time in order to assure proper clutch operation.
To check pedal free-play depress the clutch pedal, but stop and hold the moment that clutch resistance is felt. Measure the distance that the pedal traveled from the point it was released to the point where resistance was first felt. The resulting measurement is free-play.
Proper clutch free-play should be:
- If the free-play must be adjusted on Samurai models, turn the clutch cable outer nut until the proper measurement is obtained at the pedal. Once adjustment is completed, measure the amount of clutch cable that protrudes past the joint nut, it must be at least 0.196 in. (5mm).
- If the free-play must be adjusted on Sidekick, Tracker or X-90 models, turn the joint nut (2) located at the transmission end of the clutch cable in or out, as necessary to achieve the proper play. But, make sure that the outer cable nuts (3) are tightened around the center of the outer cable thread portion. Once the correct pedal free-play is obtained, check the free-play on the release arm itself (c), it should be 0.02-0.06 in. (0.5-1.5mm).
- On all models, once you are finished, check pedal adjustment and clutch function with the engine running.