service JEEP DJ 1953 Service Manual

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

H

a
0"—®
FIG.
H-67—-TWO-SPEED
WIPER
MOTOR

1—
Brush,
Commutator — Grounded - includes Terminal

2—
Spring,
brush — Commutator
3—
Insulation
Grommet, Cable

4—
Nut,
Locking
— Set Screw
5— Screw, Set — armature End Play
6—
Bearing,
Gear
Shaft
7—
Spring,
Parking Brush 8—
Brush,
Parking
9—
Nut
& Lockwasher,
Drive
Arm

10—
Screw, Securing —
Drive
Arm

11—
Arm,
Drive

12—
Screw, Fastening — Mounting
Plate

13—
Gasket,
Mounting
Plate

14—
Plate
Assembly, Parking

15—
Washer, Bowed
16—
Gear
Assembly

17—
Brush,
Commutator — Insulated

18—
Armature
Assembly

19—
Thru
Bolt,
Fastening — Motor Assembly

20—
Cap Assembly, End — includes Bearing

21—
Disc,
Thrust H-150. Major
Electrical
Component
Replacement

•
Prestolite and Delco-Remy Components

a.
Some
Prestolite and Delco-Remy electrical
components may be intermixed on a vehicle as an
approved production practice. No attempt should
be
made
to convert to a complete Prestolite or Delco-Remy system. Prestolite components should
be replaced by Prestolite components and Delco- Remy components should be replaced by Delco-
Remy components insofar as
availability
of re­ placement components
will
allow.
In
those
cases,

however, where a component is being replaced
with

one produced by the other manufacturer, make
certain factory approved service instructions are

followed
during
these
installations.
b. Distributor — No special instructions are re­

quired
for interchanging Prestolite and Delco-
Remy distributors on V6 models.
c. Starting Motor — Special instructions are re­
quired
for interchanging Prestolite and Delco-
Remy starting motors. See note
following
Par.
H-108. 219

H

ELECTRICAL
SYSTEM H-15L SERVICE
DIAGNOSIS

SYMPTOMS

Battery
Discha
rged: Shorted
Cell
in Battery......... Short in Wiring..
•
Generator Not Charging ,
Loose or Dirty Terminals
Excessive Use of Starter Excessive Use of Lights...... Insufficient Driving.........

Low
Regulator
Setting.......

Stuck
Cut-out in Regulator. ..

Low
Electrolyte
Level
in Cells

Alternator:
FAILS
TO
CHARGE:
Belt Loose Open or High Resistance in

Charging
or Ground Return
Circuit
or Battery Connections............
Excessively Worn, Open, or
Defective
Brushes.
Open Isolation
Diode.

Open Rotor (Field
Coil)

LOW
OR
UNSTEADY
CHARGING RATE:
Belt Loose.... Intermittent or High Resistance
Charging
or Ground Return
Circuit
or Battery Connections
Excessively Worn, Sticky, or Intermittent Brushes
Shorted or Open Rectifier
Diode
Grounded
or Shorted
Turns
in Rotor (Field
Coil)

Open,
Grounded, or Shorted
Turns
in
Stator

EXCESSIVE
CHARGE RATE:
Loose Connections on Alternator...........

Faulty
Regulator

NOISY
ALTERNATOR:
Defective
or Badly Worn Belt
Misaligned Belt or Pulley
Loose Pulley
Worn
Bearings.
Shorted Rectifiers

Generator:
Low
Charging Rate—
Dirty
Commutator
Poor Brush Contact.
................
Regulator Improperly Adjusted.......

High
Resistance in Charging
Circuit...
Ground
Strap Engine to Frame Broken
Loose or Dirty Terminals Slipping Generator Belt

Worn
Out Brushes

Weak
Brush Spring Tension..........

Out
of Round Commutator
PROBABLE REMEDY

Replace Battery

Check
Wiring
Circuit

Inspect Generator and Fan Belt
Clean
and Tighten

Tune
Engine

Check
Battery
Recharge Battery
Correct
Setting

Correct
Add
Distilled Water
Tighten to
Specifications
Test
and Correct
Test
Brushes and Replace if Necessary

Test
and Replace if Necessary
Test
and Replace if Necessary
Tighten to
Specifications

Test
and Correct
Test
and Replace if Necessary
Test
and Replace if Necessary

Test
and Replace if Necessary

Test
and Replace if Necessary

Check
and Correct

Check
and Correct
Replace

Align,
Replace Parts as Necessary Tighten Replace Bearings as Necessary
Test
and Replace as Necessary

Clean
Commutator
Repair
or Install New Brushes

Adjust

Clean
and Tighten Terminals Replace

Clean
and Tighten

Adjust
Belt
Install
New Brushes
Replace
Repair
220

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

H
H-151.
SERVICE
DIAGNOSIS—Continued

SYMPTOMS PROBABLE
REMEDY

Generator:
(continued)
Fails
To Charge-Open Charging Circuit Correct
Sticking Brushes Repair or Replace
Dirty
or Burned Commutator ... Clean Commutator
Grounded Commutator Replace
Open Circuit in Field Replace
Weak Soldering on Armature. . . Repair Grounded Wiring Repair

Defective
Regulator. .. Replace Regulator
Too High Charging Rate— Regulator Improperly Adjusted Adjust or Replace
Short in Armature Replace Grounded Field-to-regulator Wire Correct
Shorted
Cell
in Battery... Replace Battery

Starting
Motor: Slow Starter Speed— Discharged Battery or Shorted
Cell
Recharge or Repair
Ground
Strap Engine to Frame. Clean Terminals and Tighten
Loose or Dirty Terminals Clean and Tighten
Dirty
Commutator Clean with No. 00 Sandpaper

Worn
Out Brushes Install New Brushes
Weak Brush Spring Tension Replace

Worn
Bearings Replace Burned Starter Switch Contacts Replace Switch

Will
Not
Turn
Engine— Open Circuit at Starter Correct

Solenoid
Open or Stuck Replace
Solenoid
Starter Switch
Defective
Replace Switch
Starter Drive Broken or Stuck. Repair or Replace
Battery Discharged Recharge Battery

Distributor:
Hard
Starting— Distributor
Points
Burned or Pitted Clean
Points
or Replace (Adjust)

Breaker
Arm Stuck on Pivot Pin...... . ... . . . Clean and Lubricate

Breaker
Arm Spring Weak Replace

Points
Improperly Adjusted Adjust
Spark
Plug
Points
Improperly Set Adjust

Spark
Plug Wire Terminals in Distributor
Cap
Corroded Clean
Loose Terminals Check Circuit
Loose or Dirty Terminals on Ground Strap— Engine to Frame. Clean and Tighten
Condenser Faulty Replace Improper Ignition Timing Set Timing

Lights:
Burn
Dim— Loose or Dirty Terminals....... ........ Clean and Tighten
Leak
in Wires. Check Entire Circuit for Broken Insulation
Poor Switch Contact Install New Switch Poor Ground Connection Clean and Tighten

Aim
Headlamp Beams. Use Aiming
Chart
221

H

ELECTRICAL
SYSTEM
H-151.
SERVICE
DIAGNOSIS—Continued

SYMPTOMS
PROBABLE REMEDY

Horn
Fails
to Sound:
Broken
or Loose
Electrical
Connection Check Wiring and Connections at Horn Button and
Battery—Clean
and Tighten
Battery Low or Dead Check Battery Contact Points Burned or Broken Off. Replace Parts Necessary

Horn
Sounds Unsatisfactory Tone: Poor
Electrical
Connection Check Connections at Horn, Horn Button, Battery Battery Low Check with Hydrometer Loose Cover and Bracket Screws Tighten Bracket Bolts at Horn
Voltage at Horn too High or too Low Check with Voltmeter 222

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

H
H-152.
ELECTRICAL
SPECIFICATIONS
MODEL HURRICANE
F4 ENGINE DAUNTLESS
V-6
ENGINE

BATTERY:
Make
Model Hour Rating.

Voltage
Terminal
Ground

SPECIFIC
GRAVITY:
Fully
Charged
Recharged At
Location

GENERATOR:
Make.
Model

Ground
Polarity
Controlled Output

Control

Armature End Play
Brushes

Brush
Spring Tension

REGULATOR:
Make
Model:
For
GJP
7202,
GJP
7402A

Type
Cutout Relay: Closing
Voltage
@
Generator rpm..........
Reverse Current to Open.
Regulated
Voltage

Regulated Current

ALTERNATOR:
Make
Model
Ground
Polarity
Rated Output
Rated Field
Coil
Draw

At
70°F.
and
10-volt

Capacitor Capacity

REGULATOR:
Make
Model
Type

STARTING
MOTOR:
Make
Model
Brush
Spring Tension

LOCK
TEST:
Temperature
Amp.
(Max.)
Volt
Stall
Torque (Min.)

NO LOAD TEST:
Tempesature

Amp.
(Max.)
Volt
Rpm.
(Min.)

DRIVE:
Type

COIL:
Make.
Model

Primary
Resistance Secondary Resistance
Prestolite

HS
11-50
50 Ampere-hour
12-volts

Negative

1.260
1.225
Engine Compartment- Right Rear

Prestolite

GJP-7402A
Negative
35 amp.

CV
Regulator .003" to .010"

[0,076
a 0,25 mm.] 2
18 to 36 oz.
[510 a 1020 gr.]

Prestolite

VBO-4201E-4A
Vibrator

12.6 to 13.6 @ 1325 3 to 5 amp. 14.2 to 14.4
36 amp. max.
Motorola
A12 NW 526
Negative
35 amp.
1.7 to 2.3 amp. .1 mfd.
Motorola
R-2-K-1

Transistor

Prestolite

MDU-7004
32 to 40 oz. [907 a 1134 gr.]

70°F.
[21°C] 295 4
6 lb-ft. [0,83
kg-m.]

70°F.
[21°C.;
50
10

5300

Bendix Folo-Thru
Prestolite
200691

3.9 to 4.2
ohms

9400
to
11,700
ohms
Prestolite

HS
11-50
50 Ampere-hour
12-volts

Negative

1.260
1.225
Engine Compartment- Right Rear

Prestolite

GJP-7402A
Negative
35 amp.

CV
Regulator .003" to .010"

[0,076
a 0,25 mm.] 2
18 to 36 oz.
[510 a 1020 gr.]

Prestolite

VBO-4201E-4A
Vibrator

12.6 to 13.6 @ 1325 3 to 5 amp. 14.2 to 14.4
36 amp. max.
Motorola
A12 NW 528
Negative
35 amp.
1.7 to 2.3 amp. .1 mfd.
Motorola
R-2-K-1

Transistor
Delco-Remy

1107391,
1108366,
1108375

32 to 40 oz. [907 a 1134 gr.]
Not Applicable Not Applicable

70°F.
[21°C] 75
10.6

6200

Overrunning Clutch Delco-Remy
1115247

1.28 to 1.42
ohms

7200
to
9500
ohms
Prestolite

MHA-7008
32 to 40 oz. [907 a 1134 gr.]

70°F.
[21°C] 200 4
3 lb-ft. [0,41
kg-m.]

70°F.
[21°C] 43
10.0

9000

Bendix Folo-Thru

Prestolite
201700

4.25 to 4.60
ohms

5200
to 6100
ohms
223

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

CLUTCH

Contents

SUBJECT
PAR.

GENERAL
.1-1
Clutch
Maintenance 1-2
Clutch
Pedal Linkage and Adjustment.... 1-3
Pilot Bushing Inspection and
Replacement 1-8

CLUTCH
—HURRICANE
F4
ENGINE.
. . .1-4
Clutch
Removal. 1-5
Clutch
Pressure Plate and Disc Inspection.
.
1-6

Clutch
Pressure Plate Adjustment 1-7

Clutch
Installation 1-9

CLUTCH
—DAUNTLESS
V-6
ENGINE,
DIAPHRAGM
SPRING
TYPE
1-10

Clutch
Removal.
........
.1-11
Clutch
Inspection, Diaphragm Spring Type. . 1-12

Clutch
Installation 1-27
SUBJECT
PAR.

SERVICING COIL
SPRING
TYPE CLUTCH
. .1-13 Pressure Plate Adjustment. 1-14
Pressure Plate Disassembly. . . . . 1-15
Inspection of Parts 1-16 thru 1-20 Pressure Plate Reassembly. . . . .1-21 thru 1-23

Clutch
Lever Adjustment 1-24

Clutch
Fitxure . .1-26

CLUTCH
THROWOUT
RELEASE
BEARING
1-25

SERVICE
DIAGNOSIS
1-28

CLUTCH
SPECIFICATIONS
1-29
CLUTCH
ADJUSTING
FIXTURE
DATA
1-30

FIG.
I-1—CLUTCH
LINKAGE AND
ADJUSTMENT,
CROSS

SHAFT
TUBE
AND
LEVER
TYPE

1—
Clutch
Release Bearing
2—
Carrier
Spring
3—
Bracket

4— Dust Seal 5—
Ball
Stud 6—
Pad
7— Retainer
8—
Control
Tube Spring
9—
Control
Lever and Tube
10—
Ball
Stud and Bracket
11—
Frame
Bracket
12—
Ball
Stud Nut 13—
Yoke
Lock
Nut
14— Adjusting Yoke
15— Bolt
16— Pedal Release Rod
17— Pedal Clamp Bolt 18—
Control
Cable
19—
Clutch
Pedal
20— Screw and Lockwasher
21—
Draft
Pad 22— Pedal Pad and Shank
23— Retracting Spring
24— Pedal to Shaft Key 25— Washer
26— Pedal Shaft
27— Master Cylinder Tie Bar
28—
Control
Lever
29— Bearing
Carrier
10734

225

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

The
correct distance should be 10%"
[26,04
cm.].

If
the length of the clutch release pedal rod is
other than
10
W
[26,04
cm.], the vheicle is equipped with the early
type
Clutch
Control
Lever

and
Tube Assembly, which should be removed, and^trie latest
designed
parts should be installed.

The
free pedal clearance is adjusted by lengthening
or shortening the" clutch fork cable. To make this adjustment,
loosen
the jam nut on the cable clevis

and
lengthen or shorten the cable to obtain %"
[19,05
mm.] free travel at the pedal pad, then
tighten the jam unit.
•
Clutch
Control Cable Type

Refer
to Fig. 1-2.

a.
With the clutch pedal pad against the floor
panel, (pedal up, clutch
engaged)
adjust ball ad­
justing nut until slack is removed from the cable
and
the clutch throwout bearing contacts the clutch
pressure plate, release levers or diaphragm plate.
b. Back-off ball adjusting nut 2
V2
turns to obtain
approximately %"
[19,05
mm.] free travel.
Lock

hex nut.
FIG.

1-3—AUBURN
CLUTCH
ASSEMBLY —
HURRICANE F4 ENGINE 1—
Driven
Plate and Hub
2—
Pressure
Plate

3—
Pivot Pin
4—
Bracket
5—
Spring
Cup 6—
Pressure
Spring 7— Release
Lever

8—
Return
Spring
9—
Adjusting
Screw
10—
Jam
Nut 11—
Washer
Note:
Some older 'Jeep' vehicles may
develop
side

movement
of the clutch and brake pedals resulting
from wear of the pedals, shafts, and bushings. One way to
compensate
for this wear is to install a pedal

slack
adjuster kit 1-4.
CLUTCH
—
HURRICANE
F4
ENGINE
•
Auburn
Vehicles equipped with the Hurricane F4
engine

have a 9.25" [23,4 cm.] driven plate. The auburn clutch driving (pressure) plate assembly (Fig. 1-3)
has three pressure springs and three levers or
fingers.
1-5.
Clutch
Removal

When
necessary to remove the clutch,
follow
the procedures outlined in Section J for the removal
of the transmission and transfer case from the vehicle. Then remove the flywheel housing and use
the following procedures for removing the clutch assembly.

Note:
The F4
engine
may be removed from the
vehicle when inspecting or replacing the clutch.
Refer
to Section D for Hurricane F4
engine
re­moval and then
follow
the instructions given
below

to remove the clutch assembly.

a.
Mark
the clutch pressure plate and
engine
fly­
wheel with a center punch so the clutch assembly
may be installed in the same position after adjust­

ments
or replacement are completed.
b. Remove the clutch pressure plate bracket
bolts

equally, a little at a time, to prevent distortion and
to relieve the clutch springs evenly.
c. Remove the pressure plate assembly and driven
plate from the flywheel.
1-6.
Clutch
Pressure Plate and Disc Inspection
Inspect the pressure plate face for
cracks,
chips,

and
warpage.
Check
the pressure plate levers for
excessive
wear and the springs for breaks. If any of the
above
conditions exist, the
complete
pressure
plate must be replaced.
Check
the clutch disc for

excessive
wear,
loose
or damaged facings, broken
vibration damper springs and evidence of grease
or oil. If any of the
above
conditions exist, replace
the clutch disc.
1-7.
Clutch
Pressure Plate Adjustment —
Auburn
The
clutch pressure plate must be checked
before
installing a new or reconditioned clutch. The proper 11339

FIG.
1-4—CHECKING
AUBURN
CLUTCH
LEVER
ADJUSTMENT
1— Adjustment Gauge
2—
Fixture
Mounting Bolt

3—
Clutch
Fixture
227

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

I
Note:
The clutch release bearing is lubricated at
time of assembly and no attempt should be made
to lubricate it Refer to Fig. 1-23 when lubricating
the clutch throwout bearing collar. c. Reassembly

To
assemble the clutch to the flywheel, first put
a
small amount of light cup grease in the flywheel
pilot bushing, install the driven plate, with short
end of hub toward the flywheel, then place the pressure plate assembly in position.
With
a clutch
plate aligning arbor or a spare transmission main
shaft, align the driven plate splines leaving the
arbor
in position while tightening the pressure plate
screws evenly.
Next, assemble the flywheel housing to the
engine
and
reinstall the transmission and transfer case or
install
the
engine
in the vehicle, depending on the
procedure of removal. Make sure that the clutch
release bearing
carrier
return spring is hooked in place. For the remainder of the assembly reverse
the operations that were used in removing the
transmission and transfer case or the
engine
referring
to the instructions given in Section J for the transmission and Section D and Dl for the
engine.

d.
Adjust the clutch control cable so there is 3A" [19,05 mm.] free pedal travel. (Refer to Par. 1-3)

1-10.
CLUTCH
—
DAUNTLESS
V-6
ENGINE
•
Diaphragm Spring Type
(Early
Models)

*
Jeep' vehicles equipped with a Dauntless V-6 en­
gine
use a 10.4" [26,4 cm.] single-plate, dry-disc

clutch,
incorporating a diaphragm-type spring as­
sembly.

When
the clutch pedal is depressed, it
moves
the
clutch
fork in the direction shown in Fig. 1-8. The

clutch
fork, pivoting on a
ball
stud, acts upon the
throwout bearing. The bearing then forces the
prongs of the diaphragm spring in the direction shown in
Fig.
1-8. The diaphragm spring is mounted
so that it pivots on its retaining rings.
This
reverses
the direction of force.
Force
is applied directly to
the three retracting springs which then
move
the
pressure plate
rearward,
away from the driven plate.

The
clutch driven plate assembly slides freely on
the transmission main drive gear splined shaft. It is keyed to the gear shaft by ten splines. The
front end of the main drive gear shaft is piloted by a bushing pressed into a recess in the
rear
end
of the
engine
crankshaft. See Fig. 1-8.

The
outer area of the driven plate is divided into

segments
formed in low waves to provide springs

between
the plate facings and cushion
engagement

of the clutch. A molded facing is riveted to each
side of every
segment.
When the clutch is fully
released, the waved
segments
cause the facings to

spread
approximately .045" [1,14 mm.]. Pressure
plate movement provides an additional clearance
of approximately .030" [0.76 mm.] to assure
full
release of the driven plate. See Fig. 1-8.

The
driven plate assembly is designed to prevent
torsional fluctuation of the
engine
from being
transmitted to the transmission gears. Its hub is
FIG.
1-8—CLUTCH
RELEASE
ACTION

1—
Pressure
Plate 5—Engine
Crankshaft

2—
Throwout
Bearing
6—Pilot
Bearing

3—
Pivot
Point
7—Flywheel

4—
Clutch
Fork
8—Driven
Plate
driven
through torsional coil springs; additional

frictional
dampening is supplied by molded
fric-

tional washers.

1-11.
Clutch
Removal

a.
Remove transmission as described in Section J. b. Remove clutch throwout bearing and pedal re­

turn
spring from clutch fork.
c. Remove flvwheel housing from engine.
d.
Disconnect clutch fork from
ball
stud by forc­
ing it toward the center of the vehicle.
e.
Mark
clutch cover and flywheel with a center

punch
so that cover can later be installed in the same position on the flywheel.
This
is necessary to

maintain
engine
balance.
f. Loosen the clutch attaching
bolts
alternately,
one
turn
at a time, to avoid distorting the clutch
cover flange, until diaphragm spring is released.
g. Support the pressure plate and cover assembly
while removing last bolts; remove pressure plate
and
driven plate from flywheel.

Caution:
Use extreme care to keep clutch driven plate clean.

h.
If it is necessary to disassemble pressure plate,
remove three drive strap-to-pressure plate
bolts
and
retracting springs. Remove pressure plate from

clutch
cover.

Note:
When disassembling,
note
position of
grooves

on
edge
of pressure plate and cover. These marks must be aligned in assembly to maintain balance.

i.
The clutch diaphragm spring and two pivot rings

are
riveted to the clutch cover. Inspect spring, rings

and
cover for excessive wear or damage. If there
is a
defect,
replace the complete cover assembly.

1-12.
Clutch
inspection

Wash
all metal parts of clutch, except release bear­
ing and driven plate, in suitable cleaning solution to remove
dirt
and grease. If solvent
seeps
into

bearing,
lubricant may be dissolved. Cleaning sol­
vent
will
also damage the facings of driven plate,
a.
Inspect friction surfaces of flywheel and pres­

sure
plate for scoring or roughness. Slight roughness
may be smoothed with fine emery cloth. If surface 229

'Jeep1
UNIVERSAL
SERIES SERVICE
MANUAL

I
14172

FIG.
1-11—CLUTCH
MOUNTED
ON
ADJUSTING
FIXTURE

1— Mounting Bolt

2—
Gauge

3—
Lever

4—
Adjusting
Nut
5—
Pressure
Plate 6—
Spacer
7—
Clutch
Fixture
W-296
a.
Place the proper thickness
spacers
between the

pressure
plate face and the
clutch
adjusting
fixture.

Locate the
spacers
under the
pressure
plate fingers
and at the center of the
pressure
plate face as

shown
in Fig. I-11.

b.
With
the
spacers
properly installed,
bolt
the

pressure
plate to the adjusting
fixture.
Draw the
bolts
down evenly, a
little
at a
time,
until
they are

tight.

e. Using the proper
gage
length, check the lever
adjustment.

d.
Lever adjustment can be altered by removing
the lever clips loosening the
lock
nut and
turning

the adjusting screw in or out as required.
1-15.
Clutch
Disassembly
The
clutch
cover and
pressure
plate are under
spring
tension at all times. Therefore,
care
must be
exercised when a
clutch
cover assembly is disas­
sembled. Place the
clutch
cover assembly in an arbor
press
with
a hard
wood
block under the pres-
FIG.
1-12—COMPRESSING
SPRING

TO
REMOVE
NUTS
sure
plate. Have the block of such a length that
the cover can move down and not interfere
with

the block. Place a
wood
block
across
the top of the cover so that it
rests
on the spring
bosses
and

does
not interfere
with
the eyebolt adjusting nuts
as shown in Fig. 1-12.
Compress the
clutch
cover in the
press
until
the

clutch
release
levers are free. Remove the adjust­

ing
nuts.
Release
the
press
slowly
to prevent the
springs
from
flying
out.
Remove
felt
grease
pads.

Caution:
When
relieving
the spring
pressure,
be
sure
the cover
does
not stick on the
pressure
plate

bosses.

1-16.
INSPECTION
OF
CLUTCH
PARTS 1-17. Inspect
Clutch
Pressure
Springs

A
thorough inspection of the
clutch
springs should always be made. They should be tested for spring
tension when the spring is compressed to a given

length.
On
the
clutch
for the V6 engine, springs
with
black

color
markings, used adjacent to the
clutch
levers,
must exert a force of 240 lb. ±5 lb. [100,8 kg.
±2,3
kg.] when compressed to 1%" [3,7 cm.].
Springs
with
yellow
markings, used between springs adjacent to the
clutch
levers, must exert a force of 145 lb. ±5 lb. [65,6 kg. ±2,3 kg.] when com­

pressed
to 1%" [3,7 cm.].
1-18. Inspect
Clutch
Adjusting
Levers

A
thorough inspection should be given the levers,
the eyebolt pin, and the
fulcrum.
If they show
any wear, replace them. To remove the
release

levers,
grasp
a lever and eyebolt between the

thumb
and fingers so that the inner end of the
FIG.
1-13—REMOVING
ADJUSTING
LEVERS

l—Eyebolt
2—Fulcrum
3—Lever
231

'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL
b.
Check
the anti-rattle springs in the clutch cover

and
place the cover on top of the pressure plate
assembly. The top of each pressure spring must enter its spring seat in the cover.
Line
up punch

marks
on cover and pressure plate for balance.

c.
Slowly compress the cover making sure that
the
eyebolts
and pressure plate lugs are guided through the proper
holes
in the cover.

d.
Hold the clutch under compression and screw
down the adjusting nuts until they are flush with
the
tops
of the eyebolts. Release the spindle of
the press.

1-24.
Clutch
Lever Adjustment

Important:
Always inspect release lever height
adjustment when installing a new clutch drive
plate.

Place
a clutch
gauge
plate on the flywheel in the
position normally occupied by the driven plate.
FIG.
1-16—CLUTCH WITH GAUGE
PLATE

1—Machined
Land
2—Gauge Plate

FIG.
1-17—CHECKING
LEVERS
FOR
FREE
MOVEMENT
Mount
the cover assembly, center the plate and
line up the three machined lands on the
gauge

plate directly under the levers, as shown in
Fig.
1-16.
Tighten
the cover screws in rotation, one to two

turns
at a time, to avoid distortion of the cover.
FIG.
1-18—CLUTCH HEIGHT ADJUSTMENT
Each
lever should be depressed several times be­
fore checking.
This
will
seat the levers in their operating positions, as shown in Fig. 1-17.
Place
the
gauge
on the hub as shown in Fig. 1-18.

To
adjust the levers,
turn
the lever adjustment nut until the levers are
%{'
to %6" [0,93 a 1,59 mm.]
above the hub. Before staking the adjusting nuts
to lock them in place, work the lever up and down
and
recheck lever adjustment again. Stake the nut with a
dull
punch, as shown in Fig. 1-19.
FIG.
1-19—LOCKING ADJUSTING NUTS

1-25.
Clutch Throwout
Release Bearing

The
clutch throwout or release mechanism consists
of a forked lever which pivots on a
ball
pivot threaded into the clutch housing. A throwout lever

return
spring is anchored to a clip under the
ball

pivot and holds the lever in contact with the
ball

pivot. The clutch throwout bearing, which is a
pre-lubricated
unit, is attached to the forked end of the throwout lever.
Never wash the clutch throwout release bearing in
gasoline or any solvent that
will
dissolve the
lubri­

cant.
It is neither necessary nor possible to
lubri­

cate this bearing at any time. Connect linkage
to the throwout release lever. Adjust free-play as

directed
in Par. 1-3. 233