Clutch Disc: Service and Repair

REMOVAL
1. Raise and support vehicle.
2. Remove transmission and transfer case if equipped.





3. Support engine with wood block and adjustable jack stand. Supporting engine is necessary to avoid undue strain on engine mounts.





4. If clutch cover will be reused, mark position of cover on flywheel with paint or scriber.
5. Insert clutch alignment tool in clutch disc and into pilot bushing. Tool will hold disc in place when cover bolts are removed.





6. If clutch cover will be reused, loosen cover bolts evenly, only few threads at a time, and in a diagonal pattern. This relieves cover spring tension evenly to avoid warping.
7. Remove cover bolts completely and remove cover, disc and alignment tool.

INSTALLATION
1. Check runout and free operation of new clutch disc.
2. Lubricate crankshaft pilot bearing with MOPAR high temperature bearing grease.
3. Insert clutch alignment tool in clutch disc hub.





4. Verify that disc hub is positioned correctly. Side of hub marked Flywheel Side should face flywheel.





5. Insert alignment tool in pilot bearing and position disc on flywheel surface.
6. Position clutch cover over disc and onto flywheel.
7. Align and hold clutch cover in position and install cover bolts finger tight.
8. Tighten cover bolts evenly and a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover.
9. Tighten clutch cover bolts to following:
- 5/16 inch diameter bolts to 23 Nm (17 ft. lbs.).
- 3/8 inch diameter bolts to 41 Nm (30 ft. lbs.).





10. Remove release lever and release bearing from clutch housing. Apply MOPAR high temperature bearing grease to bore of release bearing, release lever contact surfaces, and release lever pivot stud.





11. Apply light coat of MOPAR high temperature bearing grease to splines of transmission input shaft (or drive gear) and to release bearing slide surface of the transmission front bearing retainer. Do not over lubricate shaft splines. This can result in grease contamination of disc.





12. Install release lever and bearing in clutch housing. Be sure spring clips that retain fork on pivot ball and release bearing on fork are properly installed.
13. Install clutch housing. Be sure housing is properly seated on alignment dowels before tightening housing bolts.
14. Install transmission.
15. Check fluid level in clutch master cylinder.