Clutch Disc

Remove and replace the clutch disc on a 1970 AMC Rebel Machine by separating the transmission from the engine, removing the pressure plate and clutch disc, inspecting the flywheel, and installing new components.

Warnings

Tools required

Parts

• Clutch disc × 1 — 10.5" diameter for 390ci V8
• Pressure plate (recommended replacement) × 1 — 10.5" diameter for 390ci V8
• Pilot bushing or bearing (recommended replacement) × 1 — Use OEM specification
• Release bearing/throw-out bearing (recommended replacement) × 1 — Use OEM specification
• Transmission input shaft seal (recommended replacement) × 1 — Use OEM specification
• Bell housing gasket or RTV sealant × 1 — Use OEM specification or high-temp RTV

Fluids

• Manual transmission fluid — 3.5 qt

Preparation

1. Park vehicle on level, solid ground and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect negative battery cable
4. Raise vehicle and support securely on jack stands at frame or subframe points, ensuring adequate working clearance underneath
5. Remove transmission drain plug and drain fluid into appropriate container if planning to reuse fluid; otherwise drain during removal
6. Remove driveshaft: mark orientation of rear yoke to differential, remove four U-joint retaining bolts, slide driveshaft rearward to disengage from transmission
7. Disconnect clutch linkage from clutch fork and remove linkage components from bell housing area
8. Disconnect speedometer cable from transmission
9. Disconnect backup light switch wiring connector if equipped
10. Support engine using a jack with wood block under the oil pan, positioned to prevent pan damage

Procedure

1. 1

   Support and prepare transmission for removal
   Position transmission jack under the transmission and secure with safety chain or strap. Apply slight upward pressure to take the weight off the transmission mount. The transmission jack must be centered to prevent the transmission from tipping during removal.
2. 2

   Remove transmission crossmember
   Remove the bolts securing the transmission mount to the crossmember. Remove the bolts securing the crossmember to the frame rails on both sides. Carefully lower and remove the crossmember from the vehicle. Keep hardware organized for reinstallation.
3. 3

   Remove bell housing to engine bolts
   Remove all bell housing to engine block bolts. On the 390ci V8, there are typically 4-6 bolts around the perimeter of the bell housing. The upper bolts may require a long extension or universal joint. Ensure all bolts are removed before attempting to separate the transmission.
4. 4

   Separate and remove transmission
   Carefully slide the transmission straight back on the transmission jack, ensuring the input shaft disengages from the clutch disc and pilot bushing without binding. The transmission must move rearward approximately 6-8 inches before it clears the bell housing. Keep the transmission level and aligned to prevent damaging the clutch disc. Once clear, lower the transmission and roll it out from under the vehicle.
   ⚠️Maintain firm control of transmission on jack throughout removal; sudden shifts in weight can cause tipping and serious injury
5. 5

   Inspect release bearing and fork
   With transmission removed, inspect the release bearing (throw-out bearing) for wear, noise, or rough rotation. Check the clutch fork for cracks, wear at pivot point, and wear at release bearing contact points. Remove release bearing from fork by unclipping or sliding off the input shaft bearing retainer. Remove fork by unhooking from pivot ball or pin inside bell housing.
6. 6

   Mark and remove pressure plate
   Use a center punch or paint marker to mark the pressure plate position relative to the flywheel for reassembly orientation. Install all pressure plate bolts finger tight before loosening to prevent warping. Loosen the pressure plate bolts gradually in a crossing pattern, 1-2 turns at a time, to evenly release spring tension. Once all bolts are loose, remove them completely and carefully remove the pressure plate and clutch disc assembly.
   ⚠Uneven removal of pressure plate bolts can warp the pressure plate or cause sudden spring release
7. 7

   Inspect flywheel and pilot bushing
   Inspect flywheel friction surface for heat checking, cracks, grooves, or hot spots. Minor glazing can be cleaned with sandpaper, but deep grooves require resurfacing. Check flywheel runout with a dial indicator if available; maximum runout should not exceed 0.005-0.007 inches. Inspect the pilot bushing in the center of the crankshaft for wear or damage. Remove pilot bushing using a slide hammer with internal puller or by packing with grease and driving out with a close-fitting shaft.
8. 8

   Install new pilot bushing
   Lightly lubricate the new pilot bushing outer diameter with engine oil or anti-seize. Drive the new pilot bushing squarely into the crankshaft bore using an appropriate size socket or pilot bushing driver. The bushing should be flush or slightly recessed from the crankshaft face per manufacturer specifications. Apply a small amount of high-temperature grease to the inside of the bushing.
9. 9

   Clean and prepare mounting surfaces
   Wire brush the flywheel face and pressure plate mounting surface to remove any debris, oil, or glazing. Clean the flywheel bolt holes and pressure plate bolt threads. Ensure all mating surfaces are completely free of oil, grease, or coolant contamination, as this will cause clutch slippage. Wipe surfaces with brake cleaner or denatured alcohol and allow to dry.
10. 10

    Install clutch disc and pressure plate
    Insert the clutch alignment tool through the new clutch disc hub and into the pilot bushing to center the disc. The clutch disc must be oriented correctly with the damper springs and hub offset facing the transmission side (away from flywheel). Position the new or resurfaced pressure plate onto the flywheel dowels, aligning with the marks made during removal if reusing. Install all pressure plate bolts finger tight while maintaining alignment tool position. Tighten pressure plate bolts gradually in a crossing pattern to draw the pressure plate down evenly. Follow a star pattern and tighten in 3-4 stages to full specification (typically 30-40 ft-lbs for AMC applications, but verify with manufacturer). Leave the alignment tool in place until the transmission is ready to install.
    ℹ️Incorrect clutch disc orientation will cause immediate failure; verify damper springs face transmission before tightening pressure plate
11. 11

    Install release bearing and fork
    Lubricate the clutch fork pivot ball or pin with high-temperature grease. Install the clutch fork into the bell housing, engaging it onto the pivot. Install the new release bearing onto the fork or transmission input shaft bearing retainer, depending on design. Apply a small amount of high-temperature grease to the release bearing contact points on the fork. Verify the release bearing moves freely and the fork operates smoothly through its full range of motion.
12. 12

    Prepare transmission for installation
    Inspect the transmission input shaft for burrs, scoring, or damage. Wire brush and clean the input shaft splines. Apply a very light coating of high-temperature grease to the input shaft splines - use sparingly as excess grease can contaminate the clutch disc. Replace the transmission input shaft seal if leaking or worn. Verify the bell housing gasket surface is clean or apply a thin bead of high-temp RTV sealant if gasket is not used.
13. 13

    Install transmission
    Position the transmission on the transmission jack and raise it into position behind the engine. Align the transmission input shaft with the clutch alignment tool. Carefully slide the transmission forward, ensuring the input shaft enters the pilot bushing smoothly and the transmission slides onto the engine block dowel pins. The transmission should slide fully forward until the bell housing contacts the engine block. If resistance is felt, do not force it - lower slightly, rotate the output shaft to align splines, and try again. Once fully seated, remove the clutch alignment tool through the bell housing inspection cover if accessible, or reach around to pull it out. Install all bell housing to engine bolts and tighten in a crossing pattern to draw the bell housing evenly to the block (typically 40-50 ft-lbs for AMC).
    ⚠Never use bell housing bolts to draw a misaligned transmission into position; this will damage the clutch disc and may crack the bell housing
14. 14

    Install crossmember and mount
    Raise the transmission jack to align the transmission mount with the crossmember position. Install the crossmember to the frame rails and install bolts finger tight. Install the transmission mount to crossmember fasteners and tighten. Then tighten the crossmember to frame bolts. This sequence ensures proper alignment. Remove the transmission jack once the mount is secure.
15. 15

    Reconnect components and fill transmission
    Reconnect the clutch linkage to the fork and adjust per factory specifications to achieve proper pedal height and free play. Install the driveshaft, aligning the marks made during removal, and torque U-joint strap bolts (typically 15-20 ft-lbs). Reconnect the speedometer cable and backup light switch connector. Remove the engine support jack. Fill the transmission with the correct type and quantity of manual transmission fluid through the fill plug until fluid reaches the bottom of the fill hole. Install and tighten the fill plug.

Reassembly

1. Adjust clutch linkage to achieve 1-1.5 inches of free play at the pedal before resistance is felt
2. Verify all electrical connections are secure and routed properly away from exhaust and moving components
3. Double-check that all bell housing bolts are fully tightened before operating vehicle
4. Remove jack stands and lower vehicle to ground
5. Reconnect negative battery cable

Verification

• Start the engine with clutch pedal depressed and shift through all gears to verify smooth engagement without grinding
• With engine running, verify clutch fully disengages by shifting into reverse without gear clash
• Test drive vehicle to verify smooth clutch engagement without slipping, chattering, or grabbing
• Check for proper clutch pedal feel and return; pedal should not remain on floor or feel spongy
• Inspect under vehicle after test drive for any fluid leaks from transmission or bell housing area
• Re-check clutch pedal free play after initial break-in period of 50-100 miles and adjust if necessary

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