Pressure Plate

Replace the pressure plate and related clutch components by removing the transmission, bellhousing, and clutch assembly from the 390ci V8.

Warnings

Tools required

Parts

• Pressure plate assembly × 1 — Use OEM specification for 390ci 10.5" clutch
• Clutch disc × 1 — Use OEM specification for 390ci 10.5" clutch
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Pilot bearing or bushing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Bellhousing gasket × 1 — Use OEM specification
• Clutch fork dust boot × 1 — Use OEM specification if damaged

Fluids

• Manual transmission gear oil (SAE 80W-90 or manufacturer spec) — 3.5 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect negative battery cable
4. Raise front of vehicle and support securely on jack stands under frame rails
5. Remove driveshaft: mark rear yoke position, remove four U-joint retaining bolts at rear axle, slide driveshaft rearward to disengage from transmission
6. Disconnect clutch linkage at clutch fork and frame bracket
7. Disconnect speedometer cable from transmission
8. Disconnect backup light switch wiring connector if equipped
9. Support engine from above using engine support bar or chain hoist to prevent engine from tilting when transmission is removed

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove drain plug from transmission case and allow fluid to drain completely. Inspect drained fluid for metal particles or contamination which may indicate internal transmission damage.
2. 2

   Remove transmission crossmember
   Support transmission securely with transmission jack positioned under transmission pan. Remove two bolts securing transmission mount to crossmember. Remove four bolts securing crossmember to frame rails (two per side). Lower transmission jack slightly and remove crossmember from vehicle.
3. 3

   Remove transmission mounting bolts
   Remove four bellhousing-to-engine block bolts accessible from sides and top. On AMC 390 applications, two upper bolts may require extension and universal joint. Keep bolts organized as they may be different lengths.
4. 4

   Remove transmission assembly
   Verify all connections are disconnected. Slowly slide transmission straight rearward on transmission jack to disengage input shaft from clutch disc and pilot bearing. Once input shaft clears bellhousing, carefully lower transmission and move from under vehicle. Transmission weighs approximately 80-100 lbs.
5. 5

   Remove bellhousing
   Remove remaining bellhousing bolts securing housing to engine block (typically 2-4 additional bolts). Pull bellhousing straight back to clear dowel pins and remove from engine. This exposes the clutch assembly and flywheel.
6. 6

   Mark and remove pressure plate
   If reusing pressure plate, mark its position relative to flywheel with paint or center punch for reinstallation balance. Install clutch alignment tool through clutch disc and into pilot bearing to support disc. Remove six pressure plate-to-flywheel bolts in a gradual cross pattern, loosening each bolt 2-3 turns at a time to release spring pressure evenly. Remove pressure plate and clutch disc together.
   ⚠Remove bolts gradually in cross pattern to prevent warping pressure plate and to control spring tension release.
7. 7

   Inspect flywheel and pilot bearing
   Inspect flywheel surface for heat checking, cracks, scoring, or glazing. Flywheel should be resurfaced if worn beyond 0.030" or shows significant damage. Remove pilot bearing/bushing from crankshaft using slide hammer with pilot bearing puller attachment. Inspect crankshaft pilot bore for damage.
8. 8

   Install new pilot bearing
   Lightly lubricate outer diameter of new pilot bearing with clean transmission fluid. Drive new pilot bearing squarely into crankshaft bore using appropriately sized driver or socket until seated flush with crankshaft face. Bearing should be installed with sealed side facing outward (toward transmission).
9. 9

   Clean and prepare mating surfaces
   Wire brush flywheel surface and pressure plate mounting surface. Clean all oil or grease from flywheel face using brake cleaner. Ensure flywheel bolts are torqued properly if flywheel was removed for resurfacing. Inspect clutch fork, pivot ball, and throwout bearing for wear and replace as needed.
10. 10

    Install clutch disc and pressure plate
    Place clutch disc against flywheel with longer hub side facing transmission (hub protrudes toward pressure plate). Insert clutch alignment tool through disc and into pilot bearing. Position new pressure plate over clutch disc, aligning with marks made during removal if reusing original plate, or indexing mounting holes. Start all six pressure plate bolts finger tight.
11. 11

    Torque pressure plate bolts
    Tighten pressure plate bolts gradually in a cross pattern, making multiple passes. First pass to 15-20 ft-lbs, second pass to 30-35 ft-lbs in cross pattern. Keep clutch alignment tool centered during tightening. After final tightening, verify clutch disc moves freely on alignment tool and tool can be removed and reinstalled smoothly.
12. 12

    Install throwout bearing and clutch fork
    Lightly lubricate clutch fork pivot ball and fork contact points with high-temperature grease. Install new throwout bearing onto clutch fork fingers. Install clutch fork onto pivot ball in bellhousing, ensuring fork engages throwout bearing properly. Install or replace clutch fork dust boot.
13. 13

    Reinstall bellhousing
    Install new bellhousing gasket if equipped, or ensure mating surfaces are clean. Align bellhousing over clutch assembly and onto engine block dowel pins. Install bellhousing bolts and tighten in cross pattern to secure bellhousing firmly to block. Verify clutch fork moves freely through its full range of motion.
14. 14

    Reinstall transmission
    Install new input shaft seal in transmission if removed. Lightly lubricate transmission input shaft splines with high-temperature grease. Position transmission on transmission jack and align with bellhousing. Carefully guide input shaft through throwout bearing and into clutch disc splines using clutch alignment tool as guide. Remove alignment tool once input shaft is started into clutch disc. Slide transmission forward onto bellhousing, ensuring it seats fully against bellhousing face.
15. 15

    Complete transmission installation
    Install all bellhousing-to-engine bolts and tighten securely. Install transmission crossmember and tighten frame bolts, then install transmission mount bolts. Reconnect clutch linkage, speedometer cable, backup light switch, and driveshaft (align marks made during removal). Remove engine support. Refill transmission with appropriate gear oil to specification.

Reassembly

1. Refill transmission with 3-3.5 quarts SAE 80W-90 gear oil or manufacturer specified fluid through fill plug until fluid level reaches bottom of fill hole
2. Reconnect negative battery cable
3. Adjust clutch free play according to manufacturer specifications (typically 1-1.5 inches at pedal)
4. Lower vehicle from jack stands
5. Test clutch operation before road testing to ensure proper engagement and disengagement

Verification

• Start engine and verify clutch pedal feels firm with proper resistance and returns fully
• With engine running and transmission in neutral, verify no abnormal noises from bellhousing area
• Depress clutch pedal fully and shift through all gears to verify smooth shifting with no grinding
• Perform test drive: verify clutch engages smoothly without slipping under acceleration and disengages completely without gear clash
• Check for fluid leaks around transmission input shaft seal and bellhousing
• Verify no clutch chatter or vibration during engagement from stop
• Recheck clutch linkage adjustment after 50-100 miles of operation

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