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Jeep NSG370 6 speed manual gearbox repair manual download digital

- Determine how your NSG370 clutch is actuated before doing anything
- Look under the hood for a clutch master cylinder reservoir (usually near brake master); if present it’s hydraulic.
- Look along the firewall/transmission area for a mechanical cable with an adjuster/nut; if present it’s cable-actuated.
- If the release mechanism is inside the bellhousing around the input shaft (a concentric slave) it’s hydraulic and built into the transmission bellhousing area. Most modern Jeeps with the NSG370 use hydraulic actuation (no external cable).

- Safety and preparation (do these every time)
- Park on level ground, engine off, transmission in neutral, parking brake on, wheels chocked.
- Wear safety glasses and gloves.
- Support vehicle with a jack and jack stands (not just the jack). Use rated jack stands on solid pinch-welds or frame points.
- Disconnect negative battery terminal if you will be working near electrical components or removing the transmission.

- Tools you need (descriptions and how to use them)
- Combination wrench set (metric): open-end and box-end on one tool. Use to hold or turn nuts/bolts in tight spots. For typical Jeep fasteners you’ll need 10mm–19mm.
- Metric socket set and ratchet: for faster removal/tightening of nuts and bolts. Use appropriate socket size, ensure good engagement before turning to avoid rounding bolts.
- Torque wrench (click-type, range to at least 100–150 ft·lb): applies a specific torque to bolts (critical if removing transmission/flywheel). Set to specified value, pull slowly until it clicks.
- Flat-head and Phillips screwdrivers: prying small clips and levers, turning hose clamps.
- Pliers (slip-joint and needle-nose): hold cotter pins, bend retainers, pull springs or clips.
- Adjustable wrench: general gripping when you don’t have exact wrench size.
- Flashlight or shop light: illuminates undercarriage and transmission bellhousing.
- Brake/clutch bleeding kit or handheld vacuum pump: useful for bleeding hydraulic systems. A cheap clear hose and bottle can work for gravity bleeding but pump/kit is faster and cleaner.
- Clear vinyl hose (3–6 mm id) and small catch bottle: for bleeding (hose over bleeder nipple).
- Small funnel and clean brake-fluid-compatible container: for refilling master-reservoir. Use only DOT type specified on reservoir cap.
- Feeler gauge or ruler/caliper: to measure pedal free play (mm/inches) precisely.
- Hammer and punch set: for removing cotter pins or stubborn clips.
- Pry bar: gentle leverage when separating components (use carefully).
- Wheel chocks: prevent vehicle rolling.
- Transmission jack or floor jack with wood block (plus an assistant if no tranny jack): required if you must remove the transmission to replace internal parts. A transmission is heavy and unstable—use a transmission jack.
- Clutch alignment tool (plastic bar-type): centers clutch disc when installing a new clutch. Without it you cannot correctly mate the disc to the pilot bearing.
- Service manual or repair data (shop manual): shows torque values, exact locations, and procedures for your Jeep model.

- How to identify correct pedal free play and engagement (what you measure)
- Typical clutch pedal free play: roughly 10–20 mm (0.4–0.8 in) at the top of pedal travel before the clutch fork begins to move. (Check your vehicle manual for exact spec.)
- Engagement point: pedal should begin to engage the clutch about 1/3 down from the top of travel (varies by vehicle).
- Test before adjustment: with engine off, press pedal several times to detect sponginess or binding; observe amount of free travel and any leaks or noises.

- If your Jeep is cable-actuated (adjusting the cable)
- Locate the adjustable cable end at the firewall or at the transmission/clutch fork.
- Tools used: combination wrenches/sockets to hold and turn the adjuster nut, pliers if there’s a retaining clip, ruler/feeler gauge to measure free play.
- Procedure:
- Loosen the lock nut on the cable adjuster (turn counterclockwise) while supporting the cable.
- Turn the adjuster to change free play: screw in to take up slack (reduces free play), screw out to add free play.
- Measure pedal free play at the top of travel with a ruler or feeler gauge until in spec (10–20 mm typical).
- Hold adjuster steady and re-tighten lock nut.
- Start engine, test clutch engagement in a safe area by shifting through gears and taking a low-speed drive to confirm no slipping or grabbing.
- If cable is seized, frayed, or adjuster is damaged, replace the cable. Why: a damaged cable cannot be reliably adjusted and may break, causing loss of clutch control.

- If your Jeep is hydraulic (no cable)
- There is usually no manual “adjust” — hydraulic systems are self-adjusting. Common service is bleeding to remove air or replacing leaking hydraulic parts.
- Tools used: bleed kit or vacuum pump, two wrenches (one to open bleeder, one to hold if needed), clear hose, catch bottle, funnel.
- Bleeding procedure (basic, concise):
- Check and top off master cylinder fluid reservoir with correct DOT fluid.
- Locate slave-cylinder bleeder nipple (on bellhousing area/concentric slave region). Place clear hose over nipple into bottle.
- Loosen bleeder ~1/4 turn. Have an assistant pump pedal several times and hold it down, then open bleeder to let fluid/air escape, close bleeder, release pedal. Repeat until clear fluid with no air emerges. Or use a vacuum pump on bleeder until clear fluid.
- Keep reservoir topped to avoid drawing air into system.
- Tighten bleeder, clean up, road-test.
- If bleeding does not fix spongy pedal or there is visible fluid leak at master, slave, or hose, replacement is required.

- When parts need replacement and why
- Clutch cable
- Why: frayed, stretched, seized, adjustable end threads stripped.
- Replacement: new OEM or quality aftermarket cable; replace per vehicle procedure. Re-adjust new cable to spec.
- Clutch master cylinder
- Why: internal seal failure, external leak, soft/spongy pedal that won’t firm with bleeding.
- Replacement: bench-bleed or follow manufacturer bleeding procedure after installing new master.
- Slave cylinder / Concentric Slave (CSC)
- Why: leaking slave (external or concentric inside bellhousing), failed seals, internal contamination.
- Note: concentric slave is often inside the bellhousing and commonly requires transmission removal to replace. If it’s a bolt-on external slave, replacement is simpler.
- Replacement: new slave cylinder/CSC (OEM or recommended aftermarket). If CSC, plan for full transmission removal and clutch inspection at the same time.
- Clutch disc, pressure plate, throwout bearing (complete clutch kit)
- Why: slipping under load, burning smell, difficulty engaging gears, excessive chatter, or if replacing CSC/master or removing transmission for other repairs — this is the recommended time to replace the clutch assembly and pilot bearing.
- Replacement requires transmission removal, clutch alignment tool, flywheel inspection/resurfacing, torque wrench, transmission jack, and experience.
- Pilot bearing/bushing
- Why: worn bearing causes misalignment, noise or difficulty engaging gears. Replace whenever the clutch is replaced.

- If you must remove the transmission (what extra tools and why)
- Transmission jack: safely supports and lowers transmission. Regular floor jacks are unstable for long heavy transmissions.
- Engine support bar or support for engine (if required): to hold engine when transmission mount is removed.
- Flywheel holding tool: prevents flywheel from rotating when loosening bolts.
- Clutch alignment tool: centers clutch disc for correct reinstallation.
- Torque wrench: to torque flywheel, pressure plate bolts to spec.
- Service manual: for bolt locations, torque specs, sequence, and lift points.
- Why: clutch/CSC replacement typically requires removing the transmission; doing clutch work without the proper supports and tools is dangerous and likely to damage parts.

- Testing after adjustment or repairs
- With vehicle securely supported, test pedal free play and feel.
- Start engine and test engagement in neutral, then slowly drive in a safe area checking for slipping (engine revs increase without acceleration) or grabbing (abrupt engagement).
- Re-check for fluid leaks, listen for unusual noises, and verify gear selection is smooth.

- Quick troubleshooting signs and what they mean
- Soft/spongy pedal that firms after bleeding: air in system — continue bleeding.
- Soft/spongy pedal that does not firm: internal master or slave failure — replace component.
- Pedal goes to floor and won’t return: hydraulic leak or failed master/slave — inspect and replace.
- Clutch slips under load but adjustment at cable is at minimum: clutch disc worn — replace clutch assembly.
- Fluid on bellhousing or near transmission seam: possible concentric slave leak — likely transmission removal and CSC replacement.

- Final notes (short)
- If your NSG370 has a concentric slave, be prepared for transmission removal to replace it — this is the most common reason DIYs escalate to a shop.
- If you do not have a transmission jack, torque wrench, or a safe way to support the vehicle, get professional help — clutch/transmission work can be hazardous and heavy.
- Use only manufacturer-specified fluid and parts; follow the Jeep service manual for torque specs and exact free-play values.

(End of instructions — follow safety steps exactly; replace leaking or failed hydraulic parts and worn clutch components as indicated.)
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