Clutch Assembly for the Willys Jeep
The role of the clutch is to allow engine power to be applied gradually to a vehicle starting out and interrupt power to avoid gear crunching during shifting. When the clutch is engaged power is allowed to transfer from the engine to the transmission and drive wheels. Clutch disengagement stops the power transfer and the engine is allowed to continue turning without force being transferred to the drive wheels.
The elements making up the clutch system are the pressure plate, friction disc, throwout bearing, clutch fork, clutch return spring, and pilot bushing. The flywheel is bolted to the crankshaft of the engine. The clutch friction disc is a steel disc that is located between the pressure plate and the flywheel. The throwout bearing is essential to clutch operation. When the clutch pedal is pressed down, the throwout bearing moves toward the flywheel. This moves the pressure plate away from the clutch disc, which interrupts power flow. The clutch fork and connecting linkage convert the movement of the clutch pedal to the back and forth movement of the clutch throwout bearing. To disengage the clutch, the clutch fork moves the release bearing toward the flywheel. To engage, the clutch pedal is released and the release bearing moves away from the pressure plate.
To check the proper function of the clutch try these simple tests. Have the emergency brake engaged while performing these tests.
1. Start the engine and place it in neutral. Let the clutch in and out slowly, the motion should be smooth and even.
2. Listen for odd noises like chattering, squealing, or grinding this could indicate a worn throwout bearing.
3. Put the car in 2nd or third gear and let the clutch out slowly. (make sure the car’s emergency brake is on, and you have your foot on the brake) Does the engine RPM decrease and almost stall? If it does, the clutch still has some life in it, and is doing it’s job. If the clutch slips, and the engine does not sound like it’s going to stall, there is a good chance the clutch needs to be replaced.
4. While driving does the transmission shift smoothly? If there is a crunching sound when shifting this could indicate bad synchronizers in the transmission or the clutch cable is out of adjustment.
The most common clutch problem is the friction material on the clutch disc wearing down, this can cause the clutch to slip. When it is necessary to remove the clutch, the easiest way to access it is by removal of the engine, transmission, and transfer case. Remove the flywheel housing from the engine.
-If the engine is removed for any reason, go ahead and check the clutch for wear and replace worn components as needed. The relatively low cost of the clutch components compared to the time and trouble spent gaining access to them warrants their replacement, unless they are new or in near perfect condition.
Clutch Removal
1. Mark the clutch pressure plate and engine flywheel so the clutch assembly can be installed in the same position after adjustments are done.
2. Remove four clutch adjusting bolts leaving two opposing bolts to be removed last.
3. Remove the remaining bolts equally, a little at a time, this prevents warping of the clutch pressure plate relieving the clutch springs evenly.
4. Remove the clutch assembly from the flywheel.
Caution – Do not get any oil or grease on the clutch disc lining, wash hands thoroughly before handling.
Inspect the pilot bushing while the clutch is off the transmission. The pilot bushing is pressed into the center of the flywheel. If the bushing is damaged or worn, remove it using a pilot bushing remover and replace with a new one.
Clutch Installation
Place a small amount of light cup grease in the flywheel pilot bushing, install the driven plate, with the short end of the hub toward the flywheel, place the pressure plate assembly in position. With a clutch plate aligning arbor or a spare transmission main shaft, align the driven plate splines leaving the arbor in position while tightening the pressure plate screws evenly. Next assemble the bell housing to the engine or reinstall the engine. Making sure the clutch release bearing carrier return spring is hooked in place. Finally adjust the clutch control cable so there is 1 inch free pedal travel.
Master Clutch Kit 8-1/2″ (7 piece kit) For 41-71 Jeep & Willys with 4-134 & 6-161 engine
Replaces your greasy, worn out clutch system. Ensure proper shifting. All items are factory pre-set, ready for install!!!
Call Mike @Kaiserwillys.com for details at TOLL FREE 1-888-648-4923 (Mon-Fri, 9AM-5PM EST).
New Replacement Master Clutch Kit for 8-1/2″ – Part#: 930731KM
Q: How do make sure you order the right clutch?
- A: Just make sure what you have is 8.5″ and fits the vehicles listed.
Q: I misplaced the clutch disc alignment tool. How can I get another one??
- A: You can typically just get a universal one locally. Try NAPA.
Service Manual for Universal Jeep
*Manuals : Mechanics Manuals, Owners Manuals, Master Parts Lists
*EMAIL or call Mike Toll Free (1-888-648-4923) Mon-Fri, 9am-5pm EST if you have any questions about this part or restoring your Willys.
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If you are looking for, Willys Jeep Clutch Parts, or Willys Jeep Restoration Parts and much more for your 1941-1971 Willys vehicle, you have come to the right place!
after everything is installed how far should the throw out bearing move the pressure plate springs when the clutch pedal is pushed
Hi Pete,
Its easiest to remove the bellhousing from the engine and do it from the front. There is an access cover on top the bellhousing but its tight.
It is all spring loaded so you just need to put the release cable on the left side of the fork then slide the fork thru the carrier. Make sure you have your spring on the carrier and as long as you keep tension on the cable it will stay in place.
How do i get the fork behind the bearing and over the pivot????
53 willy’s cj3b
Pete
208-245-3371
Thank you !!