Jeep Wrangler TJ 97-2006 Clutch Replacement

Removal & Installation

1. Remove transmission.
2. If original clutch cover will be reinstalled, mark position of cover on flywheel for assembly reference. Use paint or a scriber for this purpose.
3. If clutch cover is to be replaced, cover bolts can be removed in any sequence. However, if original cover will be reinstalled, loosen cover bolts evenly and in rotation to relieve spring tension equally. This is necessary to avoid warping cover.
4. Remove cover bolts and remove cover and disc. Clutch disc and pressure plate inspection

To install:

1. Lightly scuff sand flywheel face with 180 grit emery cloth. Then clean surface with a wax and grease remover.
2. Lubricate pilot bearing with Mopar®high temperature bearing grease.
3. Check runout and free operation of new clutch disc as follows:
4. Slide disc onto transmission input shaft splines. Disc should slide freely on splines.
5. Leave disc on shaft and check face runout with dial indicator. Check runout at disc hub and about 6 mm (¹/₄ in.) from outer edge of facing.
6. Face runout should not exceed 0.020 in. (0.5 mm) Obtain another clutch disc if runout exceeds this limit.
7. Position clutch disc on flywheel. Be sure side of disc marked flywheel side is positioned against flywheel. If disc is not marked, be sure flat side of disc hub is toward flywheel.
8. Inspect condition of pressure plate surface of clutch cover. Replace cover if this surface is worn, heat checked, cracked, or scored.
9. Insert clutch alignment tool in clutch disc.
10. Insert alignment tool in pilot bearing and position disc on flywheel. Be sure disc hub is positioned correctly. Side of hub marked Flywheel Side should face flywheel. If disc is not marked, place flat side of disc against flywheel.
11. Position clutch cover over disc and on flywheel.
12. Install clutch cover bolts finger tight.
13. Tighten cover bolts evenly and in rotation a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. Tightening torques are 23 ft. lbs. (31 Nm) on 2.5L engines and 38 ft. lbs. (52 Nm) on 4.0 L engines.
    • Start all 6 bolts by hand.
    • Tighten 3 pilot hole bolts ³/₂of the way (any sequence)
    • Starting 180 degrees from the last pilot bolt, tighten 3 large hole bolts three quarters of the way (any sequence)
    • Tighten 3 pilot hole bolts all the way (any sequence)
    • Starting 180 degrees from last pilot bolt, tighten 3 large bolts all the way (any sequence)
14. Apply light coat of Mopar® high temperature bearing grease to clutch disc hub and splines of transmission input shaft. Do not over lubricate shaft splines. This will result in grease contamination of disc.
15. Install transmission.

Clutch Disc Inspect

1. Clutch disc should slide freely on splined input shaft but it must not show evidence of radial play.
2. Inspect clutch linings. If linings are oiled, scorched, torn, or worn considerably, install a new clutch disc.
3. Measure disk thickness and verify there is sufficient material remaining per manufacturers recommendations.
4. Inspect clutch disc for run out at linings.
5. Inspect torsion damper for firm seating and inspect spring supporting plates for cracks. Replace clutch disc if detective.

Clutch Release Lever Inspect

Visually inspect component for damage or excessive wear. Replace, as required.

Clutch Pedal Assembly Inspect

Inspect pedal for smooth operation and ensure pedal does not catch or require uneven effort.