How to Change a Clutch in a Jeep Wrangler

by Lora Covrett
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The first Jeep was manufactured and shipped to the U.S. military in 1941. Throughout the years the Jeep model has been enhanced and redesigned but one thing remains true, Jeeps are among the toughest and most versatile vehicles around. All Jeep Wranglers had standard transmissions up until 1994. The clutch will typically last up to about 100,000 miles depending on driving habits. The clutch replacement requires auto repair experience and will take at least 15 hours.

Step 1

Jack the vehicle to a height of three cinder blocks and place jack stands under the axles. Use the cinder blocks around the frame for additional support.

Step 2

Drain and cap the transfer case and transmission after you have successfully removed the driveline and skid plate. Zip-tie the driveline to the driver's side frame.

Step 3

Secure a chain over the transmission and tighten around the transmission adapter to hold it in place after disconnecting from the engine. Remove the transfer case linkage, shift tower retainer and wiring harness before disconnecting. Be sure to also zip-tie the fuel lines safely out of the way.

Step 4

Remove the clutch fork, throwout bearing, pressure plate and clutch disk. Replace these parts with the new ones from your kit. Make sure the new clutch turns freely on the splines of the transmission input shaft. Have someone help you by holding the clutch disk in place until you can get the pressure plate secured.

Step 5

Line the transmission back up with the engine and secure it. Roll the transmission slowly to line up the docking. Keeping the transmission in neutral will allow the splines to realign themselves. After it is securely bolted to the engine, reconnect the wiring harnesses and replace and realign the shifter.

Step 6

Reconnect the transfer case shift bracket and the front and rear propeller shafts. Fill the transfer case with one quart of ATF-4 synthetic.

Step 7

Refill the transmission with approved transmission fluid listed in your owner's manual. It should take about four bottles. Replace the skid plate, remove the cinder blocks and jack stands and lower your Jeep. You're ready to go for a drive.

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