Clutch Kit

Complete replacement of the clutch disc, pressure plate, throwout bearing, and pilot bearing on a 1970 AMC Rebel Machine with 390ci V8 and manual transmission.

Warnings

Tools required

Parts

• Clutch disc (11 inch) × 1 — Use OEM specification for 390ci V8
• Pressure plate assembly × 1 — Use OEM specification for 390ci V8
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Pilot bearing (bronze bushing style) × 1 — Use OEM specification
• Clutch fork boot × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch linkage grease × 1 — High temperature bearing grease

Fluids

• Manual transmission fluid — 3 qt

Preparation

1. Park vehicle on level concrete surface and engage parking brake
2. Disconnect negative battery cable
3. Raise front of vehicle and support securely on jack stands under frame rails
4. Raise rear of vehicle and support securely on jack stands under rear axle housing
5. Remove transmission tunnel cover inside vehicle to access transmission shifter
6. Mark driveshaft and rear axle yoke alignment for reassembly reference

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove the drain plug from the transmission case and allow fluid to drain completely. If no drain plug is present, fluid will drain when transmission is lowered.
2. 2

   Disconnect driveshaft
   Remove the four U-bolt nuts securing the rear universal joint to the differential yoke. Slide driveshaft rearward to disengage from transmission output shaft. Support driveshaft and remove from vehicle. Plug transmission output shaft opening with a rag to prevent fluid loss.
3. 3

   Disconnect clutch linkage and speedometer cable
   Disconnect the clutch fork return spring from the clutch fork. Disconnect the clutch linkage rod from the clutch fork by removing the cotter pin and clevis pin. Disconnect the speedometer cable from the transmission by unscrewing the threaded collar.
4. 4

   Disconnect shift linkage
   From inside the vehicle, remove the shift lever boot and lever retaining bolts. Lift shift lever assembly out of transmission. Alternatively, disconnect external shift rods at the transmission depending on linkage configuration. Label all linkage connections for reassembly.
5. 5

   Support engine and transmission
   Position a floor jack with wood block under the engine oil pan to support engine weight. Position transmission jack securely under the transmission case. Apply slight upward pressure to support transmission weight.
6. 6

   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. Lower and remove the crossmember from vehicle.
7. 7

   Remove transmission to bellhousing bolts
   Remove all transmission-to-bellhousing bolts. There are typically four bolts accessible from under the vehicle. Note bolt locations and lengths as they may vary. Ensure transmission is securely supported on transmission jack.
8. 8

   Separate transmission from engine
   With assistant helping to stabilize, carefully slide transmission rearward on jack to disengage input shaft from clutch disc and pilot bearing. Keep transmission aligned with bellhousing opening to avoid damaging clutch components. Once input shaft clears bellhousing, lower transmission and remove from under vehicle.
   ⚠️Transmission weight shifts as it separates. Maintain firm control of transmission jack and have assistant guide the transmission.
9. 9

   Remove clutch fork and throwout bearing
   Remove the clutch fork retaining clip or spring from the ball stud in the bellhousing. Slide the clutch fork and throwout bearing assembly from the bellhousing. Separate the throwout bearing from the fork.
10. 10

    Remove pressure plate and clutch disc
    Mark the pressure plate position relative to the flywheel with a paint marker for balanced reassembly. Using a cross pattern, gradually loosen the pressure plate bolts one or two turns at a time to relieve spring pressure evenly. Once all bolts are loose, remove them completely. Remove pressure plate and clutch disc from flywheel. Note which side of clutch disc faces the flywheel.
11. 11

    Remove pilot bearing
    Inspect the pilot bearing in the center of the crankshaft. If worn or damaged, remove using a pilot bearing puller or slide hammer with appropriate adapter. For bronze bushing style bearings, use a bushing driver or carefully use a brass drift to drive out the old bushing from inside the crankshaft.
12. 12

    Inspect and clean flywheel
    Inspect flywheel surface for scoring, heat checking, cracks, or excessive wear. Check for any loose ring gear teeth. Clean flywheel surface thoroughly with brake cleaner and allow to dry. If flywheel shows damage, it must be resurfaced or replaced before proceeding. Wire brush the pressure plate mounting bolt holes to remove corrosion.
13. 13

    Install new pilot bearing
    Lightly lubricate the outer surface of the new pilot bearing or bronze bushing with high temperature grease. Drive or press the new pilot bearing into the crankshaft bore until it is fully seated and flush with the crankshaft face. Apply a small amount of grease to the inner bearing surface.
14. 14

    Install clutch disc and pressure plate
    Insert clutch alignment tool through clutch disc hub and into pilot bearing to hold disc in position. The disc damper springs or hub protrusion typically faces the transmission side. Position clutch disc against flywheel with alignment tool centered. Place pressure plate over clutch disc, aligning the marks made during removal if reusing original pressure plate. Start all pressure plate bolts by hand. Using a cross pattern, gradually tighten bolts evenly to draw pressure plate down uniformly. Tighten to manufacturer specification in multiple passes. Leave alignment tool in place until transmission is installed.
15. 15

    Install throwout bearing and clutch fork
    Apply high temperature grease to the clutch fork ball stud and fork contact points. Slide new throwout bearing onto transmission input shaft bearing retainer. Install clutch fork into bellhousing, engaging the fork fingers with the throwout bearing. Secure fork to ball stud with retaining clip or spring. Install new clutch fork boot onto bellhousing.
16. 16

    Install transmission
    Apply a thin film of high temperature grease to the transmission input shaft splines (do not over-grease). Position transmission on transmission jack and raise into position. Align input shaft with clutch disc hub using clutch alignment tool as guide. Carefully slide transmission forward, rotating output shaft slightly if needed to engage splines. Once input shaft enters pilot bearing, continue pushing transmission forward until bellhousing seats against engine block. Remove clutch alignment tool. Install all transmission-to-bellhousing bolts and tighten in a cross pattern.
17. 17

    Reinstall crossmember and remove supports
    Position transmission crossmember between frame rails. Install crossmember-to-frame bolts loosely. Align transmission mount to crossmember and install mount bolts. Tighten all crossmember and mount bolts. Remove transmission jack and engine support jack.

Reassembly

1. Reconnect shift linkage or reinstall shifter assembly using reverse of removal procedure
2. Reconnect speedometer cable and clutch linkage rod with new cotter pin
3. Install clutch fork return spring
4. Align driveshaft marks and install driveshaft to differential yoke with U-bolts
5. Refill transmission with appropriate manual transmission fluid to proper level
6. Reinstall transmission tunnel cover inside vehicle
7. Reconnect negative battery cable

Verification

• With engine off, depress clutch pedal and verify smooth operation with proper free play (typically 1 to 1.5 inches)
• Start engine and verify clutch disengages properly by shifting through all gears with engine running
• Test drive vehicle and verify smooth clutch engagement without slipping, chattering, or noise
• Check for any fluid leaks around transmission input shaft seal and drain plug
• Verify proper clutch pedal feel and that vehicle holds on incline without clutch slippage

More procedures for this vehicle