height adjustment JEEP DJ 1953 Service Manual

CLUTCH

is deeply scored or grooved, the part should be

replaced.

b. Inspect driven plate for wear or damage to fac­
ings,
loose
rivets, broken or
loose
torsion springs,

and
flattened cushion springs. If facings are worn
near
rivets or are oily, replace the plate assembly.

A
slight amount of oil on clutch facings
will
cause

clutch
grab and chatter; excessive oil on facings

will
cause slippage. It is not practical to remove
oil
with solvents or by buffing since oil
will
con­
tinue to bleed from facing material when hot. If
oil
is found on driven plate facings, examine trans­
mission drainback hole, pilot bushing,
engine
rear

main
bearing and other points of possible oil leakage. Test the fit of driven plate hub on trans­
mission main drive gear for an easy sliding fit.
c. Inspect clutch release bearing for scoring or ex­ cessive wear on front contact face. Test for rough­

ness
of balls and races by pressing and turning
front race slowly. Inspect main drive gear pilot
bushing in crankshaft. Replace bushing if it is rough or worn. Regardless of whether the old plate

or
a new plate is to be installed, check the plate
for runout. Slide the driven plate, front side first,
over the transmission main drive gear shaft so that

it
is tight on the spline. Index a
dial
indicator to the plate facing as shown in
Fig.
1-9. While holding

firmly
against front end of main drive gear, to take up play in main drive gear bearing, slowly
rotate driven plate and observe the amount of
run­

out shown by indicator. If runout of front facing
exceeds
.025" [0,635 mm.], replace the plate. It
is not practical to correct excessive runout by bending. 12769

FIG.
1-9—RUNOUT
CHECK
—
CLUTCH
PLATE
1—
Front
Facing
(Flywheel
Side)

2—
Dial
Indicator
Set
d.
Check
clutch pilot bushing for excessive wear

or
damage. Replace pilot bushing, if necessary, with

special
removal and installation
tools.
(See
Figs.

1-6 and 1-7). 1-13.
SERVICING
CLUTCH
PRESSURE
PLATE
AND

DISC
—
BORG
&
BECK
V6
(Late
Models)

The
Borg & Beck clutch is a single plate, dry disk
type. It provides smooth
engagement
of
engine
power to the wheels. The clutch consists of a pres­

sure
plate assembly with pressure springs and
release levers, and driven plate assembly. The
driven
plate assembly
uses
spring center vibration
neutralizes and two flexible facings.

The
clutch driven plate is spring cushioned with a facing riveted to both sides. The coil springs around
the hub absorb the power shocks and cushion the

driving
mechanism. The clutch throw-out bearing is of the
ball
type, packed at time of manufacture,

and
requires no further lubrication.
No adjustment for wear is provided in the clutch itself. An individual adjustment is built into the
clutch
cover to adjust the height of the release
levers.
This
adjusting nut is locked in position

and
should never be disturbed unless the clutch assembly has been disassembled for the replace­
ment of worn parts or to correct the height of the release levers.

When
the clutch pedal is depressed (disengaged),
the release bearing is moved toward the flywheel
and
contacts the inner ends of the release levers.

Each
lever is pivoted on a floating pin which re­
mains stationary in the lever and rolls across a short flat portion of the enlarged
hole
in the eye-
bolt. The outer ends of the
eyebolts
extend
through
holes
in the stamped cover and are fitted

with
adjusting nuts to secure the levers in the
correct
position. The outer ends of the release levers

engage
the pressure plate lugs by means of ful-
crums,
which provide knife-edge contact
between

the outer ends of the levers and the lugs as shown
in
Fig.
I-10. 12190

FIG.
MO—CLUTCH
LEVER
POSITIONS
A—Clutch
Engaged
B—Clutch
Disengaged 1-14.
Clutch
Pressure Plate Adjustment

The
clutch pressure plate adjustment must be
checked before installing a new or reconditioned

clutch.
The proper spacer thickness and
gage
length for a particular clutch is listed in Par. 1-30.
Use
Clutch
Adjusting
Fixture
W-296. If the W-296
fixture is not available one can be fabricated as
described in Par. 1-26. 230

'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

'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL

P
f. On vehicles without a transmission brake hold
the brake
shoes
in their relative position and
engage
the parking brake cable
into
the parking

brake
lever.
g. On vehicles without a transmission brake in­
stall
the parking brake strut and spring
between

the parking brake lever and the primary
shoe.

h.
Place the brake
shoes
on the backing plate and

install
the retainer pins, springs and retainers.

i.
Install the anchor pin plate.

j.
Install the lever and
sleeve
on the primary
shoe
then install the secondary return spring, then the
primary
return spring.

Important:
A
"L"
or "R" is located on the hex­

agon
side of the lever crank for identification. The
lever crank marked "R" applies to the primary
shoe
on the
left
rear brake assembly. The lever
crank
marked
"L"
applies to the primary
shoe
on
the right rear brake assembly.
k. Place the upper linkage rod in the
groove
of the
anchor pin and
engage
the hook of the link rod
into

the adjusting lever.

I.
Install the brake drum. Install the wheel and

tire
assembly.
m. Adjust the brakes as described
below.

P-19.
Brake
Shoe
Initial
Adjustment —

a.
Should wheel brake units have
been
disassem­ bled for any reason, an initial adjustment
MUST
be made
before
drum installation.

b.
When the brake parts have
been
installed in
their correct position, initially adjust the adjusting
screw assemblies to a point where approximately Y% [9,53 mm.] of threads are
exposed
between
the

star
wheel and star wheel nut.

Note:
Following the initial adjustment and final
assembly, check brake pedal height to ensure

brake
operation. Then drive the car in reverse and
FIG.
P-12—BRAKE SHOE ADJUSTMENT
1—
Star
Wheel
2—
Lever

3—
Screwdriver
4—
Brake
Adjusting Tool
forward,
making 10 to 15 brake applications prior
to road testing.
This
action balances the adjust­
ment of the four brake units and raises the brake
pedal.
c. Adjustment may be made manually by remov­ing the access
slot
cover and using a brake adjust­
ing
tool
or screw driver to rotate the star wheel
until
the wheel is in the locked position. To tighten, rotate the star wheel in the clockwise direction.
Then
back off the star wheel at least 15 to 20

notches
(clicks).

d.
To back off the star wheel on the brake, insert
ice pick or thin blade screw driver in adjusting screw
slot
to hold lever away from adjusting screw.

Back
off on adjusting screw until wheel and drum

turn
freely. Replace adjusting
hole
cover.

Caution:
DO NOT attempt to back off on ad­
justing screw without holding adjuster lever away from screw as adjuster
will
be damaged.
P-20. Master Cylinder Reconditioning —
Dual
System

Refer
to Fig. P-13.

DISASSEMBLY
a.
Remove the filler cap and empty all fluid.
b.
Remove the snap ring, push rod assembly, and
the primary and secondary piston assemblies. Air pressure applied in the piston
stop
hole
will
help
facilitate the removal of the secondary piston as­
sembly.
c. The residual check valves are located under
the front and rear fluid
outlet
tube
seats.

d.
The
tube
seats
must be removed with the
self-

tapping screws supplied in the repair kit to permit removal of the check valves. Screw the self-tapping
screws
into
the
tube
seats
and place two screw

driver
tips under the screw head and force the
screw upward as shown in Fig. P-14.
e. Remove the expander in the rear secondary cup, secondary cups, return spring, cup protector,
pri­

mary
cup, and washer from the secondary piston.
f. The primary piston, with the rubber cups in­ stalled, is supplied in the repair kit.

CLEANING
a.
After disassembly, immersion of all metal parts
in
clean brake fluid or a brake system cleaner is
recommended. Use air
hose
to blow out dirt and cleaning solvent from recesses and internal pas­

sages.
When overhauling a hydraulic brake unit,
use all parts furnished in the repair kit. Discard
all
old rubber parts.

b.
After cleaning, place
all"
hydraulic
system parts
on clean paper or in a clean pan.

INSPECTION
Inspect all other parts for damage or
excessive

wear.
Replace any damaged, worn, or chipped
parts.
Inspect hydraulic cylinder bore for
signs
of
scoring, rust, pitting, or etching. Any of
these
will
require
replacement of the hydraulic cylinder. 331