This guide provides a general overview. Specific procedures may vary slightly depending on the transmission (manual transmission type is crucial here - AX-5, AX-15, etc.) and engine. Always consult a repair manual specific to your Jeep's year, model, and engine for detailed instructions and torque specifications.
I. Preparation:
1. Safety First: Disconnect the negative battery cable. Use jack stands to securely support the Jeep after lifting it. Wear safety glasses and gloves.
2. Gather Tools and Parts: You'll need a complete clutch kit (pressure plate, clutch disc, throw-out bearing), a flywheel resurfacing tool (or a machine shop service), various wrenches and sockets (metric and possibly SAE), a transmission jack (essential), a clutch alignment tool, a torque wrench, pry bars, penetrating oil, and a shop manual.
3. Drain Transmission Fluid: Drain the transmission fluid before removing the transmission.
4. Disconnect Components: Disconnect the driveshaft, shifter linkage, starter motor, and any other components connected to the transmission. Take pictures as you go to aid reassembly.
II. Removal:
1. Remove Transmission: Support the transmission with the transmission jack. Carefully remove the transmission mount bolts and lower the transmission. This is the most physically demanding part of the job.
2. Inspect Flywheel: Inspect the flywheel for cracks, scoring, or excessive wear. If necessary, have it resurfaced at a machine shop. This is critical for proper clutch operation.
3. Remove Old Clutch: Remove the pressure plate bolts (usually six), then remove the pressure plate and clutch disc. Inspect the throw-out bearing. Replace this regardless of its apparent condition.
III. Installation:
1. Install New Clutch: Install the new clutch disc, ensuring it's properly seated. Use the alignment tool to properly center the clutch disc on the input shaft.
2. Install Pressure Plate: Install the new pressure plate, ensuring the bolts are evenly tightened in a star pattern. Use the specified torque from your repair manual.
3. Install Throw-Out Bearing: Install the new throw-out bearing.
4. Install Transmission: Carefully lift the transmission back into place using the transmission jack. Align the input shaft with the clutch disc and install the transmission mount bolts.
5. Reconnect Components: Reconnect all components you disconnected earlier, including the driveshaft, shifter linkage, and starter motor.
6. Refill Transmission Fluid: Refill the transmission with the correct type and amount of fluid.
IV. Post-Installation:
1. Bleed Clutch Hydraulic System: If your Jeep has a hydraulic clutch, you will need to bleed the clutch system to remove air bubbles.
2. Test Drive: Carefully test drive the Jeep, paying attention to clutch engagement, smooth shifting, and any unusual noises.
Important Considerations:
* Torque Specifications: Following the correct torque specifications is crucial to avoid damaging components.
* Alignment Tool: Using a clutch alignment tool is essential to prevent damage to the clutch disc and input shaft.
* Pilot Bearing: Inspect and replace the pilot bearing if necessary (located on the input shaft).
* Professional Help: If you are unsure about any step, seek professional help. A poorly installed clutch can lead to costly repairs or even injury.
This is a simplified overview. You absolutely must obtain a repair manual specific to your 1993 Jeep Wrangler to complete this job safely and correctly. Improper installation can result in serious damage to your vehicle and potential injury to yourself. Again, if you lack experience, hire a professional.
