Clutch Assembly Replacement
REMOVAL PROCEDURE- Tools Required
- J36221 Clutch Alignment Tool
1. Raise the vehicle. Refer to Vehicle Lifting Caution in General Information.
2. Remove the quick disconnect from the concentric slave cylinder. Refer to Master Cylinder Replacement.
3. Remove the transmission. Refer to Transmission Replacement (NV3500) or Transmission Replacement (NV4500 RWD) or Transmission Replacement (NV4500 4WD) in Manual Transmission.
4. Install the J36221 in order to support the clutch.
5. Mark the flywheel (5) and a clutch pressure plate lug for the installation alignment.
6. Remove the bolts (2) and the washers (3). Secure the clutch pressure plate (4) and the clutch driven plate (1) to the flywheel (5).
6.1. Remove the J36221
6.2. Clean all of the parts with a water dampened cloth.
6.3. Inspect all of the parts for wear and damage.
6.4. Use a straight edge in order to inspect the contact surfaces for scoring and flatness.
6.5. Inspect the friction pads for scoring, gouges, and loose rivets.
6.6. Inspect the friction pads for oil. Replace the clutch driven plate if the friction pads are soaked with oil.
6.7. Inspect all of the splines for the following:
^ Nicks
^ Burrs
^ A smooth sliding fit
6.8. Inspect all of the springs for bending and breakage.
INSTALLATION PROCEDURE
- Tools Required
- J36221 Clutch Alignment Too[
1. Install the bolts (2) and the washers (3) that secure the clutch pressure plate (4) and the clutch driven plate (1) to the flywheel (5).
2. Install the J36221 in order to support the clutch.
3. Align the marks made during removal or, if new align the lightest part of the clutch pressure plate, identified by a yellow dot, to the heaviest part of the flywheel, identified by an "X".
- Tighten the clutch pressure plate to the flywheel bolts to 41 Nm (30 ft. lbs.).
Remove the J36221.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the transmission. Refer to Transmission Replacement (NV3500) or Transmission Replacement (NV4500 RWD) or Transmission Replacement (NV4500 4WD) in Manual Transmission.
5. Install the hydraulic line fitting to the concentric slave cylinder. Refer to Master Cylinder Replacement.
6. Lower the vehicle.