Jeep Cherokee (XJ): Removal and installation

Clutch cover and disc

REMOVAL

(1) Remove transmission. Refer to procedures in Group 21.

(2) If original clutch cover will be reinstalled, mark position of cover on flywheel for assembly reference.

Use paint or a scriber for this purpose.

(3) If clutch cover is to be replaced, cover bolts can be removed in any sequence. However, if original cover will be reinstalled, loosen cover bolts evenly and in rotation to relieve spring tension equally. This is necessary to avoid warping cover.

(4) Remove cover bolts and remove cover and disc (Fig. 10).

INSTALLATION

(1) Lightly scuff sand flywheel face with 180 grit emery cloth. Then clean surface with a wax and grease remover.

(2) Lubricate pilot bearing with Mopar high temperature bearing grease.

(3) Check runout and free operation of new clutch disc as follows: (a) Slide disc onto transmission input shaft splines. Disc should slide freely on splines.

(b) Leave disc on shaft and check face runout with dial indicator. Check runout at disc hub and about 6 mm (1/4 in.) from outer edge of facing.

(c) Face runout should not exceed 0.5 mm (0.020 in.). Obtain another clutch disc if runout exceeds this limit.

(4) Position clutch disc on flywheel. Be sure side of disc marked flywheel side is positioned against flywheel (Fig. 10). If disc is not marked, be sure flat side of disc hub is toward flywheel.

(5) Inspect condition of pressure plate surface of clutch cover (Fig. 10). Replace cover if this surface is worn, heat checked, cracked, or scored.

(6) Insert clutch alignment tool in clutch disc (Fig.

11).

(7) Insert alignment tool in pilot bearing and position disc on flywheel. Be sure disc hub is positioned correctly. Side of hub marked Flywheel Side should face flywheel (Fig. 10). If disc is not marked, place flat side of disc against flywheel.

Fig. 10 Clutch Disc And Pressure Plate Inspection
Fig. 10 Clutch Disc And Pressure Plate Inspection

1 - DISC
2 - INSPECT THIS SURFACE
3 - CLUTCH COVER
4 - "FLYWHEEL SIDE" STAMPED ON THIS SURFACE

(8) Position clutch cover over disc and on flywheel (Fig. 11).

(9) Install clutch cover bolts finger tight.

(10) Tighten cover bolts evenly and in rotation a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. Tightening torques are 31 N·m (23 ft. lbs.) on 2.5L engines and 50N·m (37ft. lbs.) on 4.0 L engines.

(a) Start all 6 bolts by hand.

(b) Tighten 3 pilot hole bolts 3/4s of the way (any sequence).

Fig. 11 Typical Method Of Aligning Clutch Disc
Fig. 11 Typical Method Of Aligning Clutch Disc

1 - FLYWHEEL
2 - CLUTCH COVER AND DISC
3 - CLUTCH DISC ALIGNMENT TOOL

(c) Starting 180 degrees from the last pilot bolt, tighten 3 large hole bolts 3/4s of the way (any sequence).

(d) Tighten 3 pilot hole bolts all the way (any sequence).

(e) Starting 180 degrees from last pilot bolt, tighten 3 large bolts all the way (any sequence).

(11) Apply light coat of Mopart high temperature bearing grease to clutch disc hub and splines of transmission input shaft. Do not over lubricate shaft splines. This will result in grease contamination of disc.

(12) Install transmission.

Release bearing

REMOVAL

(1) Remove transmission.

(2) Disconnect release bearing from release lever and remove bearing (Fig. 12).

(3) Inspect bearing slide surface of transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked.

(4) Inspect release fork and fork pivot. Be sure pivot is secure and in good condition. Be sure fork is not distorted or worn. Replace release fork retainer spring if bent or damaged.

INSTALLATION

(1) Lubricate crankshaft pilot bearing with Mopart high temperature bearing grease. Apply grease to end of long shank, small diameter flat blade screwdriver.

Then insert tool through clutch disc hub to reach bearing.

(2) Lubricate input shaft splines, bearing retainer slide surface, fork pivot and release fork pivot surface with Mopart high temperature grease.

(3) Install new release bearing. Be sure bearing is properly secured to release fork.

(4) Install transmission.

Fig. 12 Release Bearing Attachment
Fig. 12 Release Bearing Attachment

1 - RETURN SPRING
2 - PIVOT BALL STUD
3 - CLUTCH HOUSING
4 - RELEASE FORK
5 - RELEASE BEARING

Pilot bearing

REMOVAL

(1) Remove transmission. Refer to Group 21, Transmission and Transfer Case, for proper procedures.

(2) Remove clutch cover and disc.

(3) Use a suitable blind hole puller to remove pilot bearing.

INSTALLATION

(1) Clean bearing bore with solvent and wipe dry with shop towel.

(2) Lubricate new pilot bearing with Mopart high temperature grease.

(3) Position and start new bearing in bearing bore by hand. Note that pilot bearing has seal at one end.

Install bearing so seal is facing outward toward transmission.

(4) Seat pilot bearing with clutch alignment tool (Fig. 13). Keep bearing straight during installation.

Do not allow bearing to become cocked. Tap bearing into place until flush with edge of bearing bore. Do not recess bearing.

(5) Install transmission. Refer to Group 21, Transmission and Transfer Case, for proper procedures.

Fig. 13 Typical Method Of Installing Pilot Bearing
Fig. 13 Typical Method Of Installing Pilot Bearing

1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - BEARING SEAL MUST FACE TRANSMISSION

Clutch housing

The clutch housing is removable and can be replaced when the transmission is out of the vehicle.

The bolts attaching the housing to the transmission case are located inside the housing (Fig. 14).

Recommended tightening torque for the clutch housing- to-transmission bolts is 46 N·m (34 ft. lbs.).

NOTE: Be sure the transmission and housing mating surfaces are clean before installing an original, or replacement clutch housing. Dirt/foreign material trapped between the housing and transmission will cause misalignment. If misalignment is severe enough, the result will be clutch drag, incomplete release and hard shifting.

Clutch hydraulic linkage

The clutch master cylinder, slave cylinder and connecting line are serviced as an assembly only. The linkage components cannot be overhauled or serviced separately. The cylinders and connecting line are sealed units. Also note that removal/installation procedures for right and left hand drive models are basically the same. Only master cylinder location is different.

Fig. 14 Clutch Housing Attachment

Fig. 14 Clutch Housing Attachment

1 - HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 - CLUTCH HOUSING
3 - TRANSMISSION

REMOVAL

(1) Raise vehicle.

(2) Remove fasteners attaching slave cylinder to clutch housing.

(3) Remove slave cylinder from clutch housing (Fig. 15).

(4) Disengage clutch fluid line from body clips, if applicable.

(5) Lower vehicle.

(6) Verify that cap on clutch master cylinder reservoir is tight. This is necessary to avoid spilling fluid during removal.

(7) Remove clutch master cylinder attaching nuts (Fig. 16) or (Fig. 17).

(8) Disengage captured bushing on clutch master cylinder actuator from pivot pin on pedal arm (Fig.

18).

(9) Slide actuator off pivot pin.

(10) Disconnect clutch interlock safety switch wires.

(11) Remove clutch hydraulic linkage through engine compartment.

Fig. 15 Slave Cylinder
Fig. 15 Slave Cylinder

1 - CLUTCH SLAVE CYLINDER

Fig. 16 Left Hand Drive Clutch Master Cylinder
Fig. 16 Left Hand Drive Clutch Master Cylinder

1 - CLUTCH MASTER CYLINDER

INSTALLATION

(1) Be sure reservoir cover on clutch master cylinder is tight to avoid spills.

(2) Position clutch linkage components in vehicle.

Work connecting line and slave cylinder downward past engine and adjacent to clutch housing (Fig. 16) or (Fig. 17).

Fig. 17 Right Hand Drive Clutch Master Cylinder
Fig. 17 Right Hand Drive Clutch Master Cylinder

1 - CLUTCH MASTER CYLINDER

Fig. 18 Clutch Pedal Attachment
Fig. 18 Clutch Pedal Attachment

1 - CLUTCH MASTER CYLINDER

(3) Position clutch master cylinder on dash panel (Fig. 16) or (Fig. 17).

(4) Attach clutch master cylinder actuator to pivot pin on clutch pedal (Fig. 18).

(5) Install and tighten clutch master cylinder attaching nuts to 38 N·m (28 ft. lbs.) torque.

(6) Raise vehicle.

(7) Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure cap on end of rod is securely engaged in lever. Check this before installing cylinder attaching nuts.

(8) Install and tighten slave cylinder attaching nuts to 23 N·m (17 ft. lbs.) torque.

(9) Secure clutch fluid line in body and transmission clips.

(10) Lower vehicle.

(11) Connect clutch interlock safety switch wires.

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