Clutch Assembly and Pilot Bearing Replacement

CLUTCH ASSEMBLY AND PILOT BEARING

CAUTION: When servicing clutch parts, do not create dust by grinding or sanding clutch disc or by cleaning parts with a dry brush or with compressed air. (A water dampened clutch - NOT SOAKED - should be used). The clutch disc contains asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.

Remove or Disconnect






Tool Required:
J-5824-01 Clutch Alignment Tool
J-1448 Pilot Bearing Puller (Gas Engine Only)
J-23907 Pilot Bearing puller (6.2L Diesel Only)

1. Transmission. Service and Repair














2. Adjusting rod (170) or the secondary cylinder (153).
- Pull back spring (166) if used.
- Retaining spring (164) if used.
3. Screws (216) and the cover (215).
4. Screws (208) and the flywheel housing (207).
5. Boot (210), the clutch fork (200) and the release bearing (212).
- Pry the clutch fork (200) off the ball stud (209).
- Pry the retainer (211) out of the clutch fork (200) if it is worn or damaged.
6. Ball stud (209).
7. Screws (206) and the spring washers (205).

Important
- Install J-5824-01 clutch alignment tool or a used clutch drive gear to support the clutch.
- Mark the flywheel, clutch cover and a pressure plate lug for alignment when installing.
- Loosen each screw one turn at a time to avoid warping the clutch cover.

8. Cover assembly (213) and the driven plate (214).
- Remove the clutch alignment tool.
9. Pilot Bearing (217) if it is worn or damaged.






Use J-1448 or J-23907 as needed.

Disassemble






1. Remove the screw (218) and straps (219).
- Note the location of the retracting springs.
2. Remove the pressure plate (220).

Clean






- All parts with a clean, water dampened cloth to remove any asbestos fibers.
- Clutch fork (200), the flywheel housing (207) and the ball stud (209) with solvent. Wipe dry.

NOTICE: The release bearing is permanently packed with lubricant and should not be soaked in cleaning solvent as this will dissolve the lubricant.

Inspect






- All parts for wear and damage.
- Contact surfaces for scoring, and flatness with a straight edge. Driven plate run-out must not be more than 5.08 mm (0.20 in).
- Friction pads for scoring, gouges and loose rivets.

Check to see if they are oil soaked.

- All splines for nicks, burrs and sliding fit.
- All springs for bending and breaks.
- Boot for tears and brittleness.

Measure






- Transmission pilot hole in the clutch housing for run out using a dial indicator. Run out should not be more than 0.380 mm (0.015 in).

Assemble






1. Install the pressure plate (220).

Important
- Line up the marks made during removal.

2. Straps (219) and the screws (218).
- Install the retracting springs in the positions they were removed from.

Install or Connect






Tool Required
J-5824-01 Clutch Alignment Tool
J-1522 Pilot Bearing Driver (Gas Engine Only)
J-34140 Pilot Bearing Driver (6.2L Diesel Only)

1. New pilot bearing (217) if needed. Use J-1522 or J-34140 as needed to drive the bearing in until the tool bottoms out.

- Gas Engine
Lubricate the bearing with a few drops of machine oil.

- 6.2L Diesel Engine
The bearing is sealed and does not need any lubrication.

2. Driven plate (214) and the cover assembly (213).

Important
- Install J-5824-01 clutch alignment tool or a used clutch drive gear to support the clutch.
- Align the marks made during removal.

3. New spring washers (205) and the screw (206).
- Remove the clutch alignment tool.

Important
- Tighten each screw one turn at a time to avoid warping the clutch cover.

NOTICE: Be careful not to use too much lubricant. Excessive lubricant may get on clutch fingers and cause slippage or damage may result to the clutch.

4. Ball stud (209).
- Pack the seat with high temperature grease.
5. Coat the rounded end of the ball stud (209) with high temperature grease.
- Pack the ball stud seat from the lubrication fitting (A) on the flywheel housing (207) (R-V models only).
6. New retainer (211) if needed.
- The retainer must be installed so the fingers and tabs fit into the release bearing groove and the retainer wraps around the flat side of the ball stud head.






7. Release bearing (212), the clutch fork (200) and the boot (210).
- Pack the inside recess (A) and the outside groove (B) of the release bearing (212) with high temperature grease as shown.
8. Flywheel housing (207) and the screws (216).
9. Cover (215) and the screws (216).














10. Adjusting rod (170) or the secondary cylinder (153) as needed.
- Retaining spring (164) if used.
- Pull back spring (166) if used.
11. Transmission. Service and Repair
12. Adjust the clutch linkage as needed.