Clutch Pack Adjustment

Cleaning and Inspection (Clutch Pack Adjustment)

Clutch Pack Shimming Procedure

^ Tools Required
- J 44295 Clutch Pack Shimming Kit

Notice: A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload can cause driveability concerns and failure of the transfer case.





1. Securely install the base plate (3) of the J 44295 in a vise with the machined surface of the locating tabs facing up.
2. Install the assembled mainshaft with the drum, the inner clutch plates, and the outer separator plates on the base plate (3) of the J 44295.
3. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
4. Place the gauge block (2) of the J 44295 on one of the locating tabs of the base plate (3) of the J 44295.
5. Using a feeler gauge measure between the gauge block (2) and the weight (1) of the J 44295.
6. Measure with the gauge block (2) and the feeler gauge on the remaining two locating tabs of the base plate (3).
7. Take the average of the three measurements and this is the required shim thickness.

Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.

8. Select from the clutch plate shim package the correct shim(s) plus or minus 0.10 mm (0.004 inch). You may use a combination of two shims to obtain the correct thickness.
The shims in the clutch plate shim package are the following thickness:
^ 0.30 mm (0.012 inch)
^ 0.56 mm (0.022 inch)
^ 0.81 mm (0.032 inch)
^ 1.04 mm (0.041 inch)
^ 1.30 mm (0.051 inch)
^ 1.55 mm (0.061 inch)
^ 1.80 mm (0.071 inch)
^ 2.08 mm (0.081 inch)
9. Remove the weight (1) of the J 44295.

Important: After obtaining the desired thickness of shims do not remove the clutch plates from the drum. Removing and then reinstalling the clutch plates could change the measurement.

10. Install the shim(s) and complete the assembly of the mainshaft.