Throwout Bearing And Lever; Pilot Bushing Replacement; Flywheel Replacement - Jeep J-10 Series 1982 Technical & Service Manual

(12) Install and tighten transfer case attaching bolts
to 30 foot-pounds (41 N»m) torque, and remove trans
mission jack.
(13) Position transfer case shift lever and shifter
shaft. Install shaft retaining nut and tighten nut
securely.
(14) Install transfer case shift control link assembly
and install link retaining pins through links and shift
rods. Use new cotter keys to retain link pins: Be sure
shift lever is properly aligned in control link assembly.
(15) Connect vent hose to transfer case vent..
(16) Connect backup light switch and 4WD indicator
switch wires.
(17) Connect speedometer cable to transfer case.
(18) Connect front and rear propeller shafts to trans
fer case yokes. Be sure to align shafts and yokes using
assembly reference marks made previously. Tighten U-
joint clamp strap bolts to 15 foot-pounds (20 N«m)
torque.
(19) Install rear crossmember. Tighten crossmember
attaching nuts to 30 foot-pounds (41 N«m) torque.
(20) Connect parking brake cable if cable was
disconnected.
(21) Install slave cylinder on clutch housing. Be sure
cylinder push rod is properly seated in throwout lever.
(22) Fill transfer case to correct level with specified
lubricant. Refer to Chapter 2D.
(23) Remove stand used to support engine and lower
vehicle.
(24) Install transmission shift lever assembly.
(25) Install screws attaching transmission shift lever
boot to floorpan.
PILOT BUSHING REPLACEMENT
Removal
(1) Remove clutch assembly. Refer to Clutch Re
moval in this section.
(2) Obtain and lubricate replacement pilot bushing
with engine oil.
<3) Remove pilot bushinglubricating wick and soak
wick in engine oil.
(4) Remove old bushing using Tool J-5822 or, pack
bushing bore with grease, insert clutch alignment tool
into bushing, and tap tool with mallet. Hydraulic pres
sure of grease will force bushing out.
(5) Clean crankshaft bore if grease was used to re
move old bushing.
Installation
(1) Install pilot bushing lubricatingwick in bushing
bore in crankshaft.
(2) Install replacement pilot bushing in crankshaft
bushing bore using Clutch Alignment Tool J-5824-01.
CLUTCH 2A-11
CAUTION: Do not allow the bushing to become cocked
during installation. The bushing and installer tool must
be kept parallel with the crankshaft centerline during
installation.
(3) Remove bushing installer tool.
(4) Install clutch, transmission, and transfer case
assemblies. Refer to Clutch Installation in this section.
THROWOUT BEARING AND LEVER
Removal
(1) Remove transmission-transfer case assembly.
Refer to Clutch Removal in this section.
(2) Remove throwout lever boot.
(3) Disconnect throwout lever spring (fig. 2A-5).
(4) Remove throwout lever and bearing as
assembly.
(5) Remove throwout bearing from lever.
Installation
(1) Fill slots in inner groove of replacement throw-
out bearing with AMC/Jeep chassis lubricant, or
equivalent.
(2) Position throwout lever on pivot ball in clutch
housing and connect lever spring to lever.
(3) Install throwout lever boot.
(4) Install throwout bearing in lever. Be sure bear
ing retaining springs are engaged in lever.
(5) Install transmission-transfer caseassembly. Re
fer to Clutch Installation in this section.
FLYWHEEL REPLACEMENT
Removal
(1) Remove clutch, transmission, and transfercase
assemblies. Refer to Clutch Removal in this section.
(2) Remove bolts attaching flywheel to crankshaft
flange and remove flywheel.
Installation
(1) Mount flywheel oncrankshaft flange and install
attaching bolts finger-tight.
(2) Tighten flywheel attaching bolts alternately and
evenly to 65 foot-pounds (88 N«m) torque.
(3) Clean surface of replacement flywheel with al
cohol to remove all traces of oil, grease, or other pro
tective substances.
(4) Install clutch, transmission, and transfer case
assemblies. Refer to Clutch Installation in this section.