Clutch Installation; Shift Lever Removal—Models T-4, T-5 - Jeep J-10 Series 1982 Technical & Service Manual

2A-10 CLUTCH
SHIFT LEVER
COVER AND
HOUSING
•-<'"•""*
81198A
Fig. 2A-7 Shift Lever Removal—Models T-4, T-5
(8) Remove bolts attaching slave cylinder to clutch
housing. Disengage cylinder push rod from throwout
lever and move cylinder aside. Secure cylinder to under-
body with wire, if necessary.
(9) Drain transfer case and disconnect speedometer
cable.
(10) Disconnect backup lamp switch wire.
(11) Disconnect parking brake cable, if necessary.
(12) Disconnect transfer case vent hose at transfer
case and disconnect 4WD indicator switch wire.
(13) Remove starter motor.
(14) Mark front propeller shaft and transfer case
yoke for assembly alignment reference.
(15) Disconnect front propeller shaft from transfer
case yoke. Move shaft aside and secure to underbody
with wire.
(16) Remove transfer case shift lever as fol
lows: Remove shifter shaft retaining nut. Remove cot
ter pins that retain shift control link pins in shift rods
and remove pins. Remove shifter shaft and disengage
shift lever from shift control links. Slide lever upward in
boot to move lever out of way.
NOTE: On some models, the shifter shaft is threaded
into the shift lever and must be unthreaded to remove it.
On other models, the shaft is removed simply by sliding
it out of the lever.
(17) Support transmission-transfer case assembly
with transmission jack. Use safety chain to secure as
sembly on jack.
(18) Remove bolts attaching transmission to clutch
housing and remove transmission-transfer case
assembly.
(19) Remove throwout bearing from throwout lever.
(20) Remove bolts attaching clutch housing to engine
and remove clutch housing.
(21) Mark position of clutch cover on flywheel for
assembly alignment reference.
(22) Loosen clutch cover attaching bolts one or two
turns at a time and in rotation to relieve spring tension
on cover.
CAUTION: The clutch cover bolts must be loosened
evenly and in rotation to avoid distorting the cover. The
cover is a steel stamping and could be warped if removed
improperly. If warped, the cover will cause clutch chat
ter after assem bly.
(23) Remove clutch cover bolts and remove cover and
driven plate from flywheel.
(24) Remove pilot bushing lubricating wick from
bushing bore in crankshaft and soak wick in clean en
gine oil.
(25) Remove bolts attaching transfer case to trans
mission adapter housing and remove transfer case from
transmission.
CLUTCH INSTALLATION
(1) Install pilot bushing lubricating wick.
(2) Insert Clutch Alignment Tool* J-5824-01 in
driven plate hub and position plate on flywheel. Be sure
alignment tool is fully seated in pilot bushing.
NOTE: Be sure the driven plate side marked fly wheel
side is positioned against the fly wheel.
(3) Position clutch cover on flywheel and over
driven plate.
(4) Align driven plate and clutch cover using align
ment tool and install cover attaching bolts finger-tight
only.
(5) Tighten clutch cover bolts alternately and
evenly to 23 foot-pounds (31 »m) torque.
CAUTION: To avoid warping the clutch cover, tighten
the cover attaching bolts a few turns at a time only.
(6) Install clutch housing on engine and install
housing attaching bolts. Tighten bolts to 54 foot-pounds
(73 N»m) torque.
(7) Install throwout bearing in throwout lever. Cen
ter bearing over clutch cover release fingers.
(8) Shift transmission into gear using long handle
screwdriver.
(9) Install transmission. Be sure to align transmis
sion clutch shaft and driven plate splines before
installation.
(10) Install and tighten transmission-to-clutch hous
ing bolts to 54 foot-pounds (73 N»m) torque.
(11) Install transfer case on transmission. Raise
transfer case using transmission jack. Align transmis
sion output and transfer case input shaft splines by
rotating output shaft yoke.