Clutch replacement problems

[w00dr0w]

I took my 03 3.7L manual trans KJ to the shop for a clutch replacement because I can't do it at my apartments.... they pulled the old clutch, but the old pressure plate is about an inch and a half taller than what should be the OEM model.... it does bolt up and is the same diameter as the old pressure plate, but when installed the clutch pedal just flops around - there is too much play to engage it. The old pressure plate is a "Valeo AMC-13" but has no other part number indicators on it.

Does anyone have any idea what is going on??! I need my Jeep this weekend for a trip, and this was supposed to be just a quick and simple clutch job!!! :help:

 

[tjkj2002]

Wrong clutch.

A bigger clutch disk would not fit.

Either way you need a new flywheel and clutch kit,you can not machine the KJ's flywheel as it is special machined with a curve.

 

[w00dr0w]

Yeah the bigger disk is what was in there before... the smaller disk is what seems to be OEM (looks the same from multiple manufacturers) but doesn't fit now... The only two things I see that could have happened is that Jeep modified the clutch design after the first few manual Libertys were made, or it is some kind of custom clutch kit.

 

[tjkj2002]

Yeah the bigger disk is what was in there before... the smaller disk is what seems to be OEM (looks the same from multiple manufacturers) but doesn't fit now... The only two things I see that could have happened is that Jeep modified the clutch design after the first few manual Libertys were made, or it is some kind of custom clutch kit.

3 types of manual tans have been used in the KJ,1 for the 2.4 gas,1 for the 3.7 till '05,and 1 for the gasser post '05.

If the clutch disk does not match the pressure plate the kit is wrong,also needs to match to the flywheel.

 

[Billwill]

Export models such as my 2002 Export 2.5 CRD came with manual gearboxes for several years...mine with 5 speed and later models with 6 speed.

As stated....clutch disk has a curve in it to match curve on flywheel.

OP needs to find OEM parts probably...the Australian site...www.ausjeepoffroad.com has a lot of Export KJ owners so they may be able to help with non OEM parts...I do not recall the 3.7 gasser coming out as a manual here in SA in 2003 but I may be wrong!