Bell Housing: Adjustments

Fig. 2 Slave cylinder & throw-out bearing assembly. Wrangler:

EXCEPT WRANGLER

Clutch housing misalignment is caused by excessive face or bore runout of the clutch housing or transmission adapter. Misalignment causes improper clutch release, clutch noise and vibration, clutch plate and front transmission bearing failure, premature pilot bearing wear, and in severe cases, gear jumps out on deceleration. If these malfunctions are evident, clutch housing alignment should be checked and corrected, as needed, using the following procedure.
1. With clutch housing assembly, pressure plate and clutch disc removed, remove one flywheel bolt.
2. Obtain a 1/2-20 bolt and nut to use as dial indicator support. Bolt should be 9 inches long for models less transmission adapter or 15 inches long for models with transmission adapter.
3. Install nut on bolt, thread bolt into crankshaft by hand, then tighten nut against flywheel to secure bolt.
4. Install clutch housing assembly, positioning shims as noted during removal, and torque bolts to 54 ft. lbs. for 4 cylinder engines, 30 ft. lbs. for V8 engines, or 35 ft. lbs. top and 45 ft. lbs. bottom for 6 cylinder engines.
5. Mount suitable dial indicator on support bolt with pointer bearing against transmission mounting face of clutch housing or adapter, approximately 1/8 inch from edge of bore. Zero indicator.
6. Rotate crankshaft a full 360° while observing dial indicator and note readings. Face runout must not exceed 0.010 inch (total indicator reading) at any point in rotation. Crankshaft endplay must be held at zero to obtain accurate readings. Move and hold crankshaft with suitable lever to eliminate endplay.
7. Reposition dial indicator so that pointer bears against center of transmission front bearing adapter bore in clutch housing or adapter, then zero indicator.
8. Holding end play at zero, rotate crankshaft a full 360° while observing indicator and note readings. Bore runout must not exceed 0.010 inch (total indicator reading).

Fig. 3 Clutch housing alignment check:

9. If either face or bore runout exceed 0.010 inch on models without transmission adapter, proceed as follows:
a. Move dial indicator aside and loosen clutch housing retaining bolts.
b. Insert shims between clutch housing and engine or engine adapter to correct misalignment. When inserting shims, note that a change in face alignment will also change bore alignment.
c. Shims inserted at point 1, affect top to bottom alignment.
d. Shims inserted at points 2 and 3, affect side to side alignment.
e. Shims inserted at points 4 and 5, affect both top to bottom and side to side alignment.
f. After inserting shims, torque housing bolts to specifications given in step 4, then recheck face and bore runout.
g. If both bore and face alignment cannot be brought within specifications, housing should be replaced.
10. If face runout exceeds 0.010 inch on models with transmission adapter, adjust as outlined in step 9.
11. If both face and bore runout exceed specifications, correct face alignment, then recheck and correct bore alignment as outlined in step 12. On models with transmission adapter, adjust adapter bore alignment as follows:
a. Move dial indicator aside, then loosen bolts securing adapter to clutch housing.
b. Reposition adapter on housing, moving adapter up or down, left or right, as needed.
c. Torque adapter bolts to 35 ft. lbs., then recheck bore runout.
13. On all models, replace clutch housing and transmission adapter, if equipped, if face and bore runout cannot be brought within specifications. Ensure that face and bore runout of replacement components is within specifications during installation.
14. When housing alignment has been set, remove dial indicator, then the housing assembly, noting installation position of shims.
15. Remove support bolt from crankshaft, install flywheel bolt and torque to specifications.
16. Install clutch disc and pressure plate assembly, then the clutch housing, insert housing shims in proper positions, then torque clutch housing bolts to specifications listed in step 4.