Disclaimer: This information is for educational purposes only. Incorrect procedures can result in injury or damage to your vehicle. Perform this repair at your own risk.
I. Preparation:
1. Safety First: Disconnect the negative battery terminal. Support the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
2. Gather Tools and Parts: You'll need a comprehensive set of tools, including sockets, wrenches (metric and possibly standard), a torque wrench (essential!), a clutch alignment tool, a transmission jack (highly recommended), and a flywheel tool (possibly, depending on the flywheel design). You'll also need the new clutch kit (pressure plate, clutch disc, throw-out bearing, pilot bearing – potentially a new release fork).
3. Drain Transmission Fluid: Drain the transmission fluid before removing the transmission.
II. Removal:
1. Disconnect Components: Disconnect the driveshaft(s), shift linkage, starter motor, and any other components connected to the transmission. Take pictures as you go to aid in reassembly.
2. Remove Transmission: Support the transmission with a transmission jack. Remove the bellhousing bolts connecting the transmission to the engine. Carefully lower the transmission. This is the heaviest and most challenging part of the job.
3. Inspect Flywheel and Pressure Plate: Inspect the flywheel for cracks or excessive wear. The pressure plate should be inspected for damage or warping. Replacement might be necessary.
4. Remove Clutch Disc and Throw-out Bearing: Remove the old clutch disc and throw-out bearing. The throw-out bearing is usually part of the pressure plate assembly and will come off with it.
III. Installation:
1. Install Pilot Bearing (if necessary): If you're replacing the pilot bearing, use the appropriate tool to press it in properly.
2. Install Clutch Disc: Carefully align the clutch disc using the alignment tool. Ensure it's properly seated.
3. Install Pressure Plate: Carefully install the new pressure plate, ensuring it's properly aligned and tightened to the specified torque according to your repair manual.
4. Install Throw-out Bearing: Install the new throw-out bearing.
5. Install Transmission: Carefully raise the transmission using the transmission jack and align it with the engine. Install the bellhousing bolts and tighten to the specified torque.
6. Reconnect Components: Reconnect all components you disconnected earlier, paying close attention to the shift linkage.
7. Refill Transmission Fluid: Refill the transmission with the correct type and amount of transmission fluid.
IV. Post-Installation:
1. Bleed the Clutch Hydraulic System (if applicable): If your Jeep has a hydraulic clutch, you'll need to bleed the system to remove any air bubbles.
2. Test Drive: Carefully test drive the vehicle, checking for smooth shifting and clutch engagement.
Essential Considerations:
* Torque Specifications: Use a torque wrench and follow the torque specifications in your repair manual precisely. Incorrect torque can lead to damage.
* Repair Manual: A repair manual specific to your 1991 Jeep Wrangler is absolutely crucial. It will provide detailed instructions, torque specifications, and diagrams.
* Professional Help: If you're not comfortable performing this repair, take your Jeep to a qualified mechanic. A botched clutch replacement can lead to significant damage and expense.
This is a highly simplified overview. The actual process is far more complex and requires detailed knowledge of automotive mechanics. Again, consult a repair manual before attempting this repair. Your safety and the well-being of your vehicle depend on it.
