Tools Required

J 38836 Bushing Installer and Clutch Arbor

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the transmission. Refer to Transmission Replacement in Manual Transmission - NV3500.
3. Mark the flywheel, cover plate, and pressure plate for installation alignment.



4. Install J 38836 through the cover plate, pressure plate, and into the flywheel for support during plate removal.



5. Remove the bolts and washers securing the clutch pressure plate and cover plate to the flywheel.
6. Remove J 38836 from the plates.
7. Clean all the clutch parts with a clean, water dampened cloth in order to remove any fibers.
8. Inspect all of the clutch parts for the following conditions:

•	Wear and damage

•	Scoring and flatness with a straight edge

•	Driven plate runout

•	The runout must not be more than 0.508 mm (0.020 in).

•	Scoring, gouges, and loose rivets on the friction pads

•	Oil soaked friction pads

•	Nicks, burrs, and sliding fit on all splines

•	Bending and breaks in the clutch pressure plate cover spring

1. Using J 38836 for installation alignment, position the pressure plate and cover plate to the flywheel.

Notice: Refer to Fastener Notice in the Preface section.




2. Secure the plates to the flywheel with bolts and washers.

•	Use the marks made during removal to align the plates if using the old clutch assembly.

•	Tighten each bolt one turn at a time in order to avoid warping the clutch pressure plate cover. Use a criss-cross pattern for tightening the bolts.

Tighten

•	Tighten the pressure and cover plate bolts for the NV1500 transmission to 44 N·m (33 lb ft).

•	Tighten the pressure and cover plate bolts for the NV3500 to 40 N·m (29 lb ft).

3. Remove J 38836 from the clutch plates.
4. Install the transmission. Refer to Transmission Replacement in Manual Transmission - NV3500.
5. Lower the vehicle.
6. Test the transmission and clutch system for proper operation.