EXJ_699 jeep xj service manual

7/29/2019 EXJ_699 jeep xj service manual

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CLUTCH

CONTENTS

page page

GENERAL INFORMATIONCLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . 1

CLUTCH HYDRAULIC FLUID . . . . . . . . . . . . . . . 2CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . 2INSTALLATION METHODS AND PARTS

USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATIONCLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . 2

DIAGNOSIS AND TESTINGCLUTCH CONTAMINATION . . . . . . . . . . . . . . . . 3

CLUTCH RUNOUT . . . . . . . . . . . . . . . . . . . . . . . 3DIAGNOSTIC CHARTS . . . . . . . . . . . . . . . . . . . 5GENERAL INFORMATION . . . . . . . . . . . . . . . . . 3

IMPROPER CLUTCH RELEASE ORENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3

MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 5SERVICE PROCEDURES

CLUTCH COMPONENT LUBRICATION . . . . . . . 5CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 10CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 5

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 11CLUTCH HOUSING REPLACEMENTAX15 . . 12

CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 14PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 14RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 13

SPECIFICATIONS

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GENERAL INFORMATION

CLUTCH COMPONENTS

The clutch mechanism consists of a single, dry-type

d isc a n d a d ia p h r a g m st y le clu t ch cove r. A h y d r a u lic

l ink a g e is u sed t o o pe r a t e t h e clu t ch r e le a se be a r in g

a n d f or k .

A n eed le-t y pe pi lot b ea r i ng i n t h e cr a n ks ha f tf la n g e s uppor t s t h e t r a n sm is si on i npu t s h a ft . A

sleeve type release bearing is used to engage and dis-

engage the clutch cover pressure plate.

The release bearing is opera ted by a release fork in

t h e clu t ch h o u sin g . Th e f o r k p ivot s on a ba l l s t u d

mounted in the housing. The release fork is actuated

by a h y d r a u lic sla ve cy l in d e r m o un t e d in t h e h o u s-

ing. The slave cylinder is operated by a clutch ma ster

cylin de r m ou n t e d on t h e d a sh p a n e l. Th e cylin de r

push rod is connected to the clutch pedal.

Th e cl ut ch d i sc h a s cu s h ion s pr i ng s i n t h e d i sc

hub. The clutch disc fa cing is r iveted t o the hub. The

f a ci n g i s m a d e f r om a n on -a s b es t os m a t e r ia l . Th e

clu t ch cove r p r essu r e p la t e is a d ia p h r a g m t y p e w it h

a one-piece spring an d multiple release fingers. The

pressure plate release fingers are preset during man-

u f a ct u r e a n d a r e n o t a d ju st a ble .

HYDRAULIC LINKAGE COMPONENTS

Th e h y d r a u lic l in ka g e con sist s of a clu t ch m a st e r

cylinder w ith integral reservoir , a clutch sla ve cylin-

der and an interconnecting fluid line.

The clutch ma ster cylinder push rod is connected

t o t h e clu t ch p ed a l . Th e sla ve cy l in d e r p u sh r od is

connected to the clutch release fork. The master cyl-

inder is mounted on the driver side of the dash panel

a d ja c en t t o t h e b r a k e m a s t er cy l in d er a n d b oos t er

assembly. This posit ioning is similar for both left an d

r ig h t h a n d d r ive m od e ls.

SAFETY PRECAUTIONS

WARNING: EXERCISE CARE WHEN SERVICINGCLUTCH COMPONENTS. FACTORY INSTALLEDCLUTCH DISCS DO NOT CONTAIN ASBESTOS

FIBERS. DUST AND DIRT ON CLUTCH PARTS MAYCONTAIN ASBESTOS FIBERS FROM AFTERMAR-KET COMPONENTS. BREATHING EXCESSIVE CON-CENTRATIONS OF THESE FIBERS CAN CAUSE

SERIOUS BODILY HARM. WEAR A RESPIRATORDURING SERVICE AND NEVER CLEAN CLUTCHCOMPONENTS WITH COMPRESSED AIR OR WITHA DRY BRUSH. EITHER CLEAN THE COMPONENTS

WITH A WATER DAMPENED RAGS OR USE A VAC-

UUM CLEANER SPECIFICALLY DESIGNED FORREMOVING ASBESTOS FIBERS AND DUST. DO NOTCREATE DUST BY SANDING A CLUTCH DISC.REPLACE THE DISC IF THE FRICTION MATERIAL IS

DAMAGED OR CONTAMINATED. DISPOSE OF ALLDUST AND DIRT CONTAINING ASBESTOS FIBERSIN SEALED BAGS OR CONTAINERS. THIS WILLHELP MINIMIZE EXPOSURE TO YOURSELF AND TO

OTHERS. FOLLOW ALL RECOMMENDED SAFETYPRACTICES PRESCRIBED BY THE OCCUPATIONALSAFETY AND HEALTH ADMINISTRATION (OSHA)AND THE ENVIRONMENTAL SAFETY AGENCY

(EPA), FOR THE HANDLING AND DISPOSAL OF

PRODUCTS CONTAINING ASBESTOS.

XJ CLUTCH 6 - 1


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CLUTCH HYDRAULIC FLUID

Th e clu t ch h y d r a u lic l in k a g e cylin de r s a n d l in es

a r e p r ef il led w it h f lu id a t t h e f a ct or y.

The hydraulic system should not require addit ional

f luid u n d e r n or m a l cir cu m st a n ces. I n f a ct , t h e r e se r-

voir fluid level w ill actua lly increase a s norma l clutch

w e a r occu r s. F o r t h is r e a so n , i t is im p or t a n t t o a voidoverfilling, or removing fluid from the reservoir. This

action will cause clutch release problems.

If inspection or diagnosis indicates addit ional f luid

may be needed, use Mopar brake fluid, or an equiv-

a le n t , m e e t ing S AE J 1703 a n d D O T 3 st a n d a r d s. D o

n ot u se a n y ot h e r t y p e of f lu id .

CLUTCH LUBRICATION

P roper clutch component lubricat ion is importan t

to satisfactory operation. Using the correct lubricant

and avoiding over lubrication are also equally impor-

t a n t .

During service, a pply recommended lubricant spar-i n gl y. D o n ot ov er l ub r ica t e a s t h i s cou ld r es u lt i n

clutch disc and pressure plate contamination.

C l ut ch a n d t r a n s m i ss ion com p on en t s r eq u ir i ng

lubrication are:

pilot bearing.

release lever pivot ball stud.

release lever pivot surfaces.

release bearing bore.

clutch pedal pivot bore and bushings.

t r a n sm ission in pu t sh a f t sp lin es a n d p ilot h u b.

r el ea s e b ea r i n g s li de s u rf a ce of f r on t b ea r i n g

retainer.

Do not apply grease to any part of the clutchcover or disc.

U s e M op a r m u lt i-m ilea g e g r ea se or a s i licon e

g r ea se f or t h e clu t ch p ed a l bu sh in g s a n d p ivot sh a f t .

U s e M o p a r h ig h t e m pe r a t u r e be a r in g g r ea se or

equivalent for the pilot bearing, release bearing bore,

t r a n s m i ss ion i n pu t s h a f t a n d r el ea s e f or k com po-

nents. Apply recommended amounts only and do not

overlubricate.

INSTALLATION METHODS AND PARTS USAGE

Distortion of clutch components during installat ion

and the use of non-standard components are common

causes of clutch malfunction.

I m p r op er clu t ch cover bolt t ig h t e n in g ca n d ist or t

t h e cov er. Th e u s ua l r es u lt i s cl ut ch g r a b , ch a t t e r

a n d r a p id w ea r .

An improperly seat ed flyw heel a nd/or clutch h ous-

in g a r e a d d it ion a l ca u ses of clu t ch f a i lu r e. I m p r op er

s ea t i n g w i l l p rod u ce m i sa l i gn m en t a n d a d d i t ion a l

clutch problems.

Th e u se of n on -st a n d a r d or low q u a li t y p a r t s w il l

a lso le a d t o p r o blem s a n d w e a r . U se r e com m e n d ed

factory parts only.

A cock ed p ilot bea r in g is a n o t h e r ca u se o f clu t ch

n oi se , d r a g , h a r d s h if t in g , a n d r a p id b ea r i n g w e a r.

Alw a y s u se a n a l ig n m e n t t o o l t o in st a l l a n e w be a r -

in g . Th is p r a ct ice h e lp s a vo id cockin g t h e bea r in g

d u r in g in st a l la t ion .

DESCRIPTION AND OPERATION

CLUTCH OPERATION

L ev er a g e, cl a m pi n g f or ce , a n d f r ict i on a r e w h a t

make the clutch work. The disc serves as the fr ict ion

e le m e n t a n d a d ia p h r a g m sp r in g a n d p r e ssu r e p la t e

provide the clamping force. The clutch pedal, hydrau-

l ic l in k a g e, r el ea s e l ev er a n d b ea r i n g p rov id e t h e

leverage.

The clutch cover assembly clamps the disc against

the flywheel. The assembly consists of the cover, dia-

p h r a g m sp r in g , p r essu r e p la t e , a n d f u lcr u m com p o-

n en t s . Th e p res s ur e p la t e cl a m ps t h e cl ut c h d is ca g a i ns t t h e f ly w h eel a n d t h e s pr in g pr ov id es t h e

clamping force.

T h e clu t ch d isc f r ict io n m a t e r ia l is r ive t e d t o t h e

disc hub. The hub bore is splined for installat ion on

t h e t r a n sm ission in pu t sh a f t . Th e h u b sp lin es con -

n e ct t h e d isc t o t h e t r a n sm ission .

The clutch linkage uses hydra ulic pressure t o oper-

at e the clutch. The clutch ma ster cylinder push rod is

con n e ct e d t o t h e clu t ch p ed a l a n d t h e sla ve cy l in d e r

p us h r od i s con n ect e d t o t h e r el ea s e l ev er i n t h e

clutch housing.

Depressing the clutch pedal develops fluid pressure

in the clutch master cylinder. This pressure is trans-m i t t ed t o t h e s la v e cy li n der t h r ou g h a con n ect i n g

lin e . I n t u r n , t h e sla ve cy l in d e r o p e r a t e s t h e clu t ch

release lever.

Th e cl ut ch r el ea s e b ea r i ng i s m ou n ted on t h e

t r a n sm ission f r on t bea r in g r e t a in er. Th e bea r in g is

a t t a ch e d t o t h e r e le a se le ve r , w h ich m o ve s t h e be a r -

i n g i n t o c on t a c t w i t h t h e cl ut ch cov er d ia p h r a g m

spring.

S l a v e cy li n der f or ce ca u s es t h e r el ea s e l ev er t o

m ov e t h e r el ea s e b ea r i n g i n t o con t a c t w i t h t h e d ia -

p h ra g m s pr i ng . As a d d i t ion a l f or ce i s a p pl ied , t h e

bea r in g p r esses t h e d ia p h r a g m sp r in g f in ge r s in w a r d

on t h e f u lcr u m s. Th i s a c t ion m ov es t h e p re ss u replate rearward relieving clamp force on the disc. The

cl ut ch d is c i s d i se ng a g ed a n d f r ee w h ee li n g a t t h i s

point.

The process of clutch re-engagement is simply t he

reverse of wha t occurs during disengagement. R eleas-

ing pedal pressure removes clutch linkage pressure.

The release bearing moves away from the diaphragm

s pr in g w h ich a l low s t h e pr es su r e pl a t e t o ex er t

clamping force on the clutch disc.

6 - 2 CLUTCH XJ

GENERAL INFORMATION (Continued)


3/16

DIAGNOSIS AND TESTING

GENERAL INFORMATION

P r o bl em d ia g n os i s w i l l g en er a l ly r eq u ir e a r oa d

t es t t o d et er m in e t h e t y pe of f a ul t . C om pon en t

i n sp ect i on w i l l t h en d et e rm i n e t h e p rob le m ca u s e

a f t e r r o a d t e st in g .Drive the vehicle at normal speeds during the road

t e st . S h i ft t h e t r a n s m is s ion t h r ou g h a l l g e a r r a n g es

and observe clutch action.

If chatter, grab, slip, or improper release is experi-

e n ce d, r e m ove a n d in spe ct t h e clu t ch com p on e n t s.

However, if t he problem is noise or h ar d shift ing, fur-

t h e r d ia g n osis m a y be n e e d ed . Th e t r a n sm ission or

a n ot h er d r iv el in e com pon en t m a y a ct u a ll y b e a t

f a u lt . C a r e f u l o bse r va t ion d u r in g t h e t e st w il l h e lp

n a r r o w t h e p r o ble m a r e a .

CLUTCH CONTAM INATION

F lu id con t a m in a t ion is a f r eq u e n t ca u se of clu t chm a lf u n ct ion s. O il , g r ea se , w a t e r, or ot h e r f luid s on

t h e clu t ch con t a ct su r f a ce s w ill ca u se f a u lt y op er a -

t io n . T h e u su a l r e su lt is ch a t t e r , s l ip a n d g r a b.

During inspection, note if any components are con-

t a m in a t e d . L ook f or e vid en ce o f oi l, g r ea se , clu t ch

hydra ulic fluid, or wa ter/road splash on clutch com-

ponents.

O il con t a m i n a t i on i n di ca t e s a l ea k a t e it h er t h e

r e a r m a in se a l o r t r a n sm issio n in p u t sh a f t . O il le a k s

p r od u ce a r e sid u e o f o i l o n t h e h o u sin g in t e rior a n d

on t h e cl ut ch cov er a n d f ly w h eel . H ea t b ui ld up

ca u sed by sl ip pa g e bet w e e n t h e clu t ch cover , d isc,

and flywheel can sometimes bake the oil residue onto

t h e com p on e n t s. Th e g la z e-lik e r e sid u e r a n g e s in

color from amber to black.

R oa d s pl a s h con t a m i n a t i on m ea n s d i rt /w a t e r i s

entering the clutch h ousing. This m ay be due t o loose

bolt s , h ou sin g cr a ck s, o r t h r o ug h t h e sla ve cyl ind e r

op en i ng . D r i vi n g t h r ou g h d ee p w a t e r p ud d le s ca n

f or ce w a t e r/r oa d s pl a s h i n t o t h e h ou s in g t h r ou g h

such openings.

C lu t ch f lu id l ea k s a r e f rom l oos e or d a m a g ed

clu t ch l in ka g e f lu id l in e s or con n e ct ion s. H o w e ve r,

most clutch fluid leaks will usually be noted and cor-

rected before severe conta mina tion occurs.

Grease contamination is usually a product of exces-

sive lubrication during clutch service. Apply only a

s m a l l a m ou n t of g r ea s e t o t h e i n p ut s h a f t s pl in es ,

bearing retainer, pilot bearing, release fork and pivot

st u d . Ex ce ss g r e a se ca n be t h r o w n o f f d u r in g o p e r a -

t io n a n d co n t a m in a t e t h e d isc.

IMPROPER CLUTCH RELEASE OR ENGAGEMENT

Clutch release or engagement problems are caused

b y w e a r, or d a m a g e t o on e or m or e cl ut ch com p o-

nents. A visual inspection of the release components

w il l u su a lly r e ve a l t h e p r oblem p a r t .

Re le a se p r oblem s ca n r e su lt in h a r d sh ift in g a n d

noise. I tems to look for are: leaks at the clutch cylin-

d er s a n d in t er con n e ct in g l in e ; loose sla ve cy l in d e r

bolt s ; w o r n /loose r e le a se f or k a n d p ivot st u d ; d a m -

aged release bearing; and a worn clutch disc, or pres-sure plate.

N or m a l c on d e n s a t i on i n v eh i cl es t h a t a r e s t or e d o r

ou t of s er v ice f or l on g p er i od s of t i m e ca n g en er a t e

enough corrosion to ma ke the disc st ick t o the flywheel ,

or pressure plate. I f this condit ion is experienced, cor-

r e ct i on on l y r e q u ir e s t h a t t h e d i s c b e l oos e n ed m a n u -

al ly through the inspection plate opening.

En g a g e m e n t p r oblem s u su a lly r e su lt in sl ip , ch a t -

ter/shudd er, a nd n oisy operat ion. The prima ry ca uses

a r e clu t ch d isc con t a m in a t ion ; clu t ch d isc w e a r ; m is-

a l ig n m en t , or d ist or t ion ; f ly w h e e l d a m a g e; or a com -

b in a t i on of t h e f or eg oi n g. A v is u a l i n sp ect i on i s

r e q u ir e d t o d e t e r m in e t h e p a r t a ct u a lly ca u sin g t h eproblem.

CLUTCH RUNOUT

CLUTCH DISC

C h eck t h e cl ut ch d is c b ef or e i n st a l l a t i on . Ax ia l

(face) runout of a new disc should not exceed 0.5 mm

(0.020 in.). Mea sur e run out a bout 6 mm (1/4 in.) from

the outer edge of the disc facing. Obtain another disc

if runout is excessive.

CLUTCH COVER

Check condition of the clutch cover before installa-t ion . A w a r p ed cover or d ia p h r a g m sp r in g w il l ca u se

grab and incomplete release or engagement. Be care-

ful when handling the cover and disc. Impact can dis-

tort the cover, diaphragm spring, release fingers and

t h e h u b of t h e clu t ch d isc.

Use an alignment tool when posit ioning the disc on

the flywheel. The tool prevents accidental misalign-

ment which could result in cover distortion and disc

d a m a g e .

A f r eq u en t ca u s e of cl u t ch cov er d i st or t i on i s

improper bolt t ightenin g. To avoid w a rping t he cover,

t h e bolt s m u st be t ig h t en e d in a d ia g on a l p a t t e r n a n d

on ly 2 3 t h r e a d s a t a t im e t o t h e sp ecif ied t o r q u e.

FLYWHEEL

Flywheel runout should not exceed 0.08 mm (0.003

i n .). M ea s u r e r u n ou t a t t h e ou t er e dg e o f t h e f ly -

w h e e l f a ce w it h a d ia l in d ica t or. Mo u n t t h e in d ica t o r

on a s t u d i n st a l l ed i n p la c e o f o n e of t h e f ly w h e el

bolts.

Common causes of runout are:

h ea t w a r p a g e.

improper ma chining.

XJ CLUTCH 6 - 3


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1 Check clutch housing bolts. Tighten if loose. Besure housing is fully seated on engine block.

2 Check flywheel. Scuff sand face to remove glaze.

Clean surface with wax and grease remover.

Replace flywheel if severely scored, worn orcracked. Secure flywheel with new bolts (ifremoved). Do not reuse old bolts. Use Mopar

Lock NSeal on bolts.

3 Tighten clutch cover bolts 2-3 threads at a time,alternately and evenly (in a star pattern) to

specified torque. Failure to do so could wrap thecover.

4 Check release fork. Replace fork if bent or worn.Make sure pivot and bearing contact surfaces are

lubricated.

5 Check release fork pivot (in housing). Be surepivot is suecure and ball end is lubricated.

6 Transmission input shaft bearingwillcause noise,chatter, or improper release if damaged. Checkcondition before installing transmission.

7 Check slave cylinder. Replace it if leaking. Be

sure cylinder is properly secured in housing andcylinder piston is seated in release fork.

8 Check input shaft seal if clutch cover and disc

were oil covered. Replace seal if worn, or cut.

Clutch Components

9 Inspect release bearing slide surface of trans.front bearing retainer. Surface should be smooth,free of nicks, scores. Replace retainer ifnecessary. Lubricate slide surface before

installing release bearing.

10 Do not replace release bearing unless actuallyfaulty. Replace bearing only if seized, noisy, ordamaged.

11 Check clutch cover diaphragm spring and releasefingers. Replace cover if spring or fingers arebent, warped, broken, cracked. Do not tamperwith factory spring setting as clutch problems will

result.

12 Check condition of clutch cover. Replace clutchcover if plate surface is deeply scored. warped,

worn, or cracked. Be sure cover is correct sizeand properly aligned on disc and flywheel.

13 Inspect clutch housing. Be sure bolts are tight.Replace housing if damaged.

14 Verify that housing alignment dowels are inposition before installing housing.

15 Clean engine block surface before installing

clutch housing. Dirt, grime can producemisalignment.

16 Make sure side of clutch disc marked flywheel

side is toward flywheel.

17 Check rearmain sealif clutchdisc and cover were

oil covered. Replace seal if necessary.18 Check crankshaft flange (if flywheel is removed).

Be sure flance is clean and flywheel bolt threadsare in good condition.

19 Check pilot bearing. Replace bearing if damaged.

Lube with Mopar high temp. bearing greasebefore installation.

20 Check transmission input shaft. Disc must slidefreely on shaft splines. Lightly grease splines

before installation. Replace shaft if splines or pilotbearing hub are damaged.

21 Check flywheel bolt torque. If bolts are loose,replace them. Use Mopar Lock NSeal to securenew bolts.

22 Check clutch disc facing. Replace disc if facing ischarred, scored, flaking off, or worn. Also check

runout of new disc. Runout should not exceed 0.5mm (0.02 in.).

6 - 4 CLUTCH XJ

DIAGNOSIS AND TESTING (Continued)


5/16

incorrect bolt tightening.

improper seating on crankshaft f lange shoulder.

f or e ig n m a t e r ia l on cr a n k sh a f t f la n g e .

Flywh eel m achining is not recommended. The fly-

wheel clutch surface is machined to a unique contour

a n d m a c h in i ng w i ll n eg a t e t h i s f ea t u r e . H ow e ve r,

m i n or f ly w h ee l s c or i ng ca n b e cl ea n e d u p b y h a n dw it h 180 g r i t e m er y, or w it h su r f a ce g r in d in g e q u ip-

m e n t . Re m ove o n ly e n ou g h m a t e r ia l t o r e d uce scor -

in g (a p p r ox im a t e ly 0.001 - 0.003 in .). H e a vy st ock

removal is not recommended. Replace the flywheelif scoring is severe a nd deeper tha n 0.076 mm (0.003

in .). Ex ce ssive st o ck r e m ova l ca n r e su lt in f lyw h e e l

cr a c ki n g o r w a r p a g e a f t er i n st a l l a t i on ; i t ca n a l s o

weaken the flywheel and interfere with proper clutch

release.

C l ea n t h e cr a n k s ha f t f la n g e b ef or e m ou n t in g t h e

f ly w h e e l . D ir t a n d g r e a se o n t h e f la n g e su r f a ce m a y

cock the flywheel causing excessive runout. Use new

b ol t s w h e n r em ou n t in g a f ly w h e el a n d s ecu r e t h ebo lt s w it h Mo p a r Lock And Seal. Tighten flywheel

bolts to specified torque only. Overtightening can dis-

t o r t t h e f ly w h e e l h u b ca u sin g r u n o u t .

MISALIGNMENT

C lu t ch h ou sin g a l ig n m e n t is im por t a n t t o p r o pe r

clu t ch op er a t io n . Th e h ou sin g m a in t a in s a l ig n m en t

b et w een t h e cr a n ks h a ft a n d t r a n sm is si on i npu t

s h a f t . M is a l ig n m en t ca n ca u s e cl ut ch n oi se , h a r d

sh ift in g , in com p le t e r e le a se a n d ch a t t e r. I t ca n a lso

r e su lt in p r e m a t u r e w e a r o f t h e p ilo t be a r in g , co ve r

release fingers and clutch disc. In severe cases, mis-

a l ig n men t ca n a l so ca u s e pr em a t u r e w ea r of t h et r a n sm issio n in p u t sh a f t a n d f r o n t be a r in g .

H ou si ng m is a li gn m en t i s g en er a ll y ca u s ed b y

incorrect seating on the engine or tra nsmission, loose

housing bolts, missing alignment dowels, or housing

d a m a g e. Ti gh t en a l l t h e cl ut ch h ou si ng b ol t s t o

p r op er t o r q u e be for e in st a l l in g a n y st r u t s . Also be

su r e a l ig n m en t d ow e ls a r e in p la ce a n d sea t e d in t h e

b lock a n d h ou s in g b ef or e b ol t t i g ht e ni n g. I n f re -

quently, misalignment may also be caused by housing

m ou n t in g su r f a ce s t h a t a r e n ot com p le t ely p a r a l lel .

Misalignment can be corrected with shims.

DIAGNOSTIC CHARTSThe diagnosis charts describe common clutch prob-

l em s , ca u s es a n d cor r ect i on . F a u l t con d it i on s a r e

listed at the top of each chart . Conditions, causes and

cor r e ct ive a ct ion a r e ou t l in ed in t h e in d ica t e d col-

u m n s.

SERVICE PROCEDURES

CLUTCH COMPONENT LUBRICATION

P roper clutch component lubricat ion is importa nt

to satisfactory operation. Using the correct lubricant

and not over lubricating are equally important . Apply

r e com m e n d ed lu br ica n t sp a r in gly t o a vo id d isc a n dpressure plate contamination.

C l ut ch a n d t r a n s m i ss ion com p on en t s r eq u ir i ng

lubrication are:

Pilot bearing.

Release lever pivot ball stud.

Release lever contact surfaces.

Release bearing bore.

Clutch disc hub splines.

Clutch pedal pivot shaft bore.

Clutch pedal bushings.

I n p u t sh a f t sp lin es.

I n p u t sh a f t p i lo t h u b.

Tr a n sm ission f r on t bea r in g r e t a in er sl id e su r -face.

NOTE: Never apply grease to any part of the clutchcover, or disc.

RECOMMENDED LUBRICANTS

U s e M op a r m u lt i-p u r pose g r ea se f or t h e clu t ch

p ed a l b u sh i ng s a n d p iv ot s h a f t . U s e M o pa r high

temperature grease (or equivalent) for all other lubri-

ca t ion r e q u ir e m en t s. Ap ply r e com m e n d ed a m o u n t s

and do not over lubricate.

CLUTCH LINKAGE FLUID

The int egral clutch ma ster cylinder reservoir, sla ve

cylinder and fluid lines are pre-filled with fluid prior

to assembly operations.


fluid under normal circumstances. In fact , the reser-voir fluid level will actually increase as normalclutch wear occurs. For this reason, it is impor-tant to avoid overfilling, or removing fluid fromthe reservoir. This will cause clutch releaseproblems.


may be needed, use Mopar brake fluid, or an equiv-a le n t m e et in g st a n d a r d s S AE J 1703 a n d D O T 3. D o

n o t u se a n y o t h e r t y p e o f f lu id .

XJ CLUTCH 6 - 5

DIAGNOSIS AND TESTING (Continued)


6/16

CONDITION POSSIBLE CAUSES CORRECTION

DISC FACING WORN OUT 1. Normal wear. Driver frequently

rides (slips) clutch. Results in rapidwar overheating. Insufficient clutchcover diaphragm spring tension.

1. Replace clutch disc. Also replace

cover if spring is weak or pressureplate surface is damaged.

CLUTCH DISC FACINGCONTAMINATED WITH OIL,GREASE, OR CLUTCH FLUID

1. Leak at rear main seal or attransmission input shaft seal.Excessive amount of grease

applied to input shaft splines. Roadsplash, water entering housing.Slave cylinder leaking.

1. Replace leaking seals. Apply lessgrease to input shaft splines.Replace clutch disc (do not clean

and reuse). Clean clutch coverand reuse only if cover is in goodcondition. Replace slave cylinder ifleaking.

CLUTCH IS RUNNING PARTIALLYDISENGAGED

1. Release bearing sticking-binding.Does not return to normal runningposition.

1. Verify that bearing is actuallybinding, the replace bearing andtransmission front bearing retainer

if sleeve surface is damaged.

FLYWHEEL HEIGHT INCORRECT 1. Flywheel surface improperly

machined. Too much stockremoved or surface is tapered.

1. Replace flywheel.

WRONG DISC OR PRESSURE

PLATE INSTALLED

1. Incorrect parts order or model

number.

1. Replace with correct parts.

Compare old and new parts beforeinstallation.

CLUTCH DISC, COVER AND/ORDIAPHRAGM SPRING, SARPED,DISTORTED

1. Rough handling (impact) bentcover, spring, or disc. Incorrect bolttightening sequence and methodcaused warped cover.

1. Install new disc or cover asneeded. Follow installation/tightening instructions.

FACING ON FLYWHEEL SIDE OFDISC TORN, GOUGED, WORN

1. Flywheel surface scored andnicked.

1. Reduce scores and nicks bysanding or surface grinding.Replace flywheel if scores-nicks

are deeper than .002-.004 inch.CLUTCH DISC FACING BURN

(CHARRED). FLYWHEEL ANDCOVER PRESSURE PLATESURFACES HEAVILY GLAZED

1. Frequent operation under high

loads or hard accelerationconditions. Driver frequently rides(slips) clutch. Results in rapid wearand overheating of disc and cover.

1. Scuff sand flywheel. Replace

clutch cover and disc. Alert driverto problem cause.

6 - 6 CLUTCH XJ

SERVICE PROCEDURES (Continued)


7/16


CLUTCH DISC WARPED 1. New disc not checked for axial

runout before installation.

1. Replace disc. Be sure runout of

new disc is less than .5 mm (.020in.).

CLUTCH DISC BINDS ON INPUT

SHAFT SPLINES

1. Clutch disc hub splines damaged

during installation. Input shaftsplines rough, damaged.Corrosion, rust formations on

splines of disc and input shaft.

1. Clean, smooth and lubricate disc

and shaft splines. Replace discand/or input shaft if splines areseverely damaged.

CLUTCH DISC RUSTED TOFLYWHEEL AND/OR PRESSURE

PLATE

1. Occurs in vehicles stored, or notdriven for extended periods of

time. Also occurs after steamcleaning if vehicle is not used forextended period.

1. Remove clutch cover and disc.Sand rusted surfaces clean with

180 grit paper. Replace disc cover,and flywheel if corrosion is severe.

CLUTCH DISC FACING STICKS TOFLYWHEEL

1. Vacuum may form in pockets overrivet heads in clutch disc. Occursas clutch cools down after use.

1. Drill 1/16 inch diameter holethrough rivets and scuff sand discfacing with 180 grit paper.

CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.PILOT BEARING SEIZED, LOOSE,OR ROLLERS ARE WORN

1. Bearing cocked during installation.Bearing defective. Bearing notlubricated. Clutch misalignment.

1. Lubricate and install new bearing.Check and correct anymisalignment.

CLUTCH WILL NOT DISENGAGEPROPERLY

1. Low clutch fluid level. 1. Top off reservoir and check forleaks.

2. Clutch cover loose. 2. Tighten bolts.

5. Clutch cover diaphragm spring

bent or warped during transmissioninstallation.

5. Replace cover.

6. Clutch disc installed backwards. 6. Remove and reinstall disccorrectly. Be sure disc sidemarked to flywheel is actuallytoward flywheel.

7. Release fork bent or fork pivot isloose or damaged.

7. Replace fork and pivot if worn ordamaged.

8. Clutch master or slave cylinderfault.

8. Replace master and slave cylinderas assembly.

XJ CLUTCH 6 - 7



8/16


CLUTCH DISC FACING COVERED

WITH OIL, GREASE, OR CLUTCHFLUID

1. Oil leak at rear main or input shaft

seal.

1. Correct leak and replace disc (do

not clean and reuse the disc).

2. Too much grease applied to

splines or disc and input shaft.

2. Apply lighter grease coating to

splines and replace disc (do notclean and reuse the disc).

CLUTCH DISC AND/OR COVERWARPED, OR DISC FACINGSEXHIBIT UNUSUAL WRONG TYPE

1. Incorrect or substandard parts. 1. Replace disc and/or cover withcorrect parts.

CLUTCH MASTER OR SLAVECYLINDER PLUNGER DRAGGING-BINDING

1. Master or slave cylindercomponents worn or corroded.

1. Replace both cylinders asassembly (and reservoir).

NO FAULT FOUND WITH CLUTCHCOMPONENTS

1. Problem actually related tosuspension or driveline component.

1. Further diagnosis required. Checkengine/transmission mounts,

propeller shafts and U-joints, tires,suspension attaching parts and

other driveline components asneeded.

2. Engine related problem. 2. Check EFI and ignition systems.

PARTIAL ENGAGEMENT OFCLUTCH DISC (ONE SIDEWORN-OPPOSITE SIDE GLAZEDAND LIGHTLY WORN)

1. Clutch pressure plate positionsetting incorrect or modified.

1. Replace clutch cover and disc.

2. Clutch cover, spring, or release

fingers bent, distorted (roughhandling, improper assembly).

2. Replace clutch cover and disc.

3. Clutch disc damaged or distorted. 3. Replace disc.

4. Clutch misalignment. 4. Check alignment and runout of

flywheel, disc, or cover and/orclutch housing. Correct asnecessary.

6 - 8 CLUTCH XJ



9/16

CONDITION POSSIBLE CAUSE CORRECTION

Clutch components damaged or worn

out prematurely.

1. Incorrect or sub-standard clutch

parts.

1. Replace with parts of correct type

and quality.

Pilot bearing damaged. 1. Bearing cocked during installation.

Bearing not lubricated prior to

installation. Bearing defect.

1. Replace bearing. Be sure it is

properly seated and lubricated

before installing clutch.2. Clutch misalignment. 2. Check and correct misalignment

caused by excessive runout offlywheel, disc, cover or clutchhousing. Replace input shaft ifbearing hub is damaged.

Loose components. 1. Attaching bolts loose at flywheel,cover, or clutch housing.

1. Tighten bolts to specified torque.Replace any clutch bolts that are

damaged.

Components appear overheated.

Hub of disc cracked or torsiondamper springs are distorted or

broken.

1. Frequent high load, full throttle

operation.

1. Replace parts as needed. Alert

driver to condition causes.

Contact surface of release bearingdamaged.

1. Clutch cover incorrect, or releasefingers are bent or distortedcausing damage.

1. Replace clutch cover and bearing.

2. Release bearing defect. 2. Replace bearing.

3. Release bearing misaligned. 3. Check and correct runout of clutch

components. Check front bearingretainer sleeve surface. Replace ifdamaged.

Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.

Clutch pedal squeak. 1. Pivot pin loose. Pedal bushingsworn out or cracked.

1. Tighten pivot pin. Replacebushings if worn or damaged.Lubricate pin and bushings withsilicone base lubricator chassis

grease.

XJ CLUTCH 6 - 9



10/16

CLUTCH FLUID LEVEL

The clutch fluid reservoir , ma ster cylinder, slave

cylin de r a n d f lu id l in e s a r e p r e -f i lled w it h f lu id a t

the factory during assembly operations.


fluid under normal circumstances. In fact , the reser-

voir fluid level will actually increase as normalclutch wear occurs. For this reason, it is impor-tant to avoid overfilling, or removing fluid fromthe reservoir.


may be needed, use Mopar brake fluid, or an equiv-

a le n t m e et in g st a n d a r d s S AE J 1703 a n d D O T 3. D o

n ot u se a n y ot h e r t y p e of f lu id .

Clutch fluid level is checked at the master cylinder

reservoir (Fig. 1). An indicator ring is provided either

on the side, or interior r im of the reservoir (Fig. 2).

B e s ur e t o w i pe t h e r es er v oi r a n d cov er cl ea n

before removing the cover. This will avoid having dirt

or f or ei gn m a t e r ia l f a l l i n t o t h e r es er v oi r d u r in g afluid level check.

FLYWHEEL

I n s pe ct t h e f ly w h ee l w h e n ev er t h e cl ut ch d is c,

cover a n d h ou sin g a r e r e m oved f or se rvice . C h e ck

co n d it io n o f t h e f ly w h e e l f a ce , h u b, r in g g e a r t e e t h ,

and flywheel bolts.

Min o r scr a t ch e s, bu r r s, o r g la z in g o n t h e f ly w h e e l

face can be reduced with 180 grit emery cloth. How-ever, the flywheel should be replaced if the disc con-

ta ct sur face is severely scored, heat checked, cracked,

or obviously worn.

Flywh eel m achining is n ot recommended. The fly-

wheel surface is manufactured with a unique contour

t h a t w ou ld b e n eg a t ed b y m a ch in in g . H ow e ver,

cleanup of minor flywheel scoring can be performed

by h a n d w it h 180 g r i t e m e r y , o r w it h su r f a ce g r in d -

i n g e q ui pm en t . R ep la c e t h e f ly w h e el i f s cor i ng i s

deeper than 0.0762 mm (0.003 in.).

H e a v y s t ock r em ov a l b y g r in d in g i s not recom-mended. Ex cessive st ock r e m ova l ca n r e sult in f ly-

w h e e l cr a ck in g o r w a r p a g e a f t e r in st a l la t io n . I t ca na lso w e a k e n t h e f ly w h e e l a n d in t e r f e r e w it h p r o p e r

clutch release.

C h eck f ly w h ee l r u n ou t i f m i sa l i gn m en t i s s u s-

p ect ed . Ru n ou t sh ou ld n ot e xcee d 0.08 m m (0.003

i n .). M ea s u r e r u n ou t a t t h e ou t er e dg e o f t h e f ly -

w h e e l f a ce w it h a d ia l in d ica t or . Mou n t t h e d ia l in d i-

cator on a stud installed in place of one of the clutch

housing at taching bolts.

C l ea n t h e cr a n k s ha f t f la n g e b ef or e m ou n t in g t h e

f ly w h e e l . D ir t a n d g r e a se o n t h e f la n g e su r f a ce m a y

cock the flywheel causing excessive runout.

C h e ck con d it ion of t h e f ly w h e e l h u b a n d a t t a ch in g

bolts. Replace the flywheel if the hub exhibits cracks

in t h e a r e a o f t h e a t t a ch in g bo lt h o le s.

I n st a l l n e w a t t a ch in g bo lt s w h e n e ve r t h e f ly w h e e l

is r e p la ce d a n d u se Mo p a r Lock N Seal, or Loctite

242 on the replacement bolt threads.

Recommended flywheel bolt torques are:

142 Nm (105 ft. lbs.) for 6-cylinder flywheels

6 8 N m ( 5 0 f t . l b s . ) p l u s a n a d d i t i o n a l t u r n o f

60 for 4-cylinder flyw heels

I n s p e c t t h e t e e t h o n t h e s t a r t e r r i n g g e a r . If theteeth are worn or damaged, the flywheel shouldbe replaced as an assembly. This is the recom-mended and preferred method of repair.

I n ca se s w h e r e a n e w f ly w h e e l is n o t r e a d ily a va i l-

a ble , a r e p la ce m e n t r in g g e a r ca n be in st a l le d . H o w -

ever, the following precaut ions must be observed t o

a vo id d a m a g in g t h e f ly w h ee l a n d r e pla cem e n t g ea r .

(1) Mark posit ion of t he old gea r for a lignment ref-

e re nce on t h e f ly w h e el . U s e a s cr i be r f or t h i s p ur -

pose.

(2) We a r p r ot e ct ive g og g le s or a p p r oved sa f e t y

g la sses. Also w e a r h e a t r e sist e n t g love s w h e n h a n -

d lin g a h e a t e d r in g g e a r .

Fig. 1 Clutch Master Cylinder Reservoir And Cap

RESERVOIR CAPCLUTCH MASTER CYLINDERRESERVOIR FLUID LINE

Fig. 2 Reservoir Fluid Level Indicator Ring

CLUTCH MASTERCYLINDER RESER-VOIR FLUID LEVEL INDICA-TOR RING

6 - 1 0 CLUTCH XJ



11/16

(3) Remove the old gear by cutt ing most of the way

t h r ou g h i t (a t on e p oi n t ) w i t h a n a b r a s i ve cu t -of f

wheel. Then complete removal with a cold chisel or

punch.

(4) Th e r in g g ea r is a sh r in k f i t o n t h e f ly w h e el .

This means the gear must be expanded by heating in

or d er t o i n st a l l i t . The method of heating andexpanding the gear is extremely important.Eve r y su r f a ce of t h e g e a r m u st be h ea t e d a t t h e sa m e

time to produce uniform expansion. An oven or simi-

lar enclosed hea ting device must be used. Tempera -

ture required for uniform expansion is approximat ely

375 F.

CAUTION: Do not use an oxy/acetylene torch toremove the old gear, or to heat and expand a new

gear. The high temperature of the torch flame cancause localized heating that will damage the fly-wheel. In addition, using the torch to heat a replace-

ment gear will cause uneven heating andexpansion. The torch flame can also anneal thegear teeth resulting in rapid wear and damage afterinstallation.

(5) Th e h ea t e d g ea r m u s t b e i n st a l l ed e ve nl y t o

a vo id m isa l ign m e n t or d ist or t ion . A sh o p p r e ss a n d

s u it a b l e p r es s p la t e s s h ou l d b e u s ed t o i n st a l l t h e

g ea r i f a t a l l p ossible.

(6) B e su r e t o w e a r e y e a n d h a n d p r o t e ct io n . H e a t

r es is t en t g lov es a n d s a f et y g og g le s a r e n ee de d f or

p e r so n a l sa f e t y . Also u se m e t a l t o n g s, vise g r ip s, o r

s im i la r t ool s t o p os it i on t h e g ea r a s n ece ss a r y f or

installat ion.(7) Allo w t h e f ly w h e e l a n d r in g g e a r t o co o l d o w n

before installat ion. Set the assembly on a workbench

a n d let i t cool in n or m a l sh op a ir.

CAUTION: Do not use water, or compressed air tocool the flywheel. The rapid cooling produced by

water or compressed air can distort, or crack thegear and flywheel.

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC

REMOVAL

(1) R em ov e t r a n sm is si on . R ef er t o G r ou p 21,

Tran smission an d Tra nsfer Ca se, for proper proce-

dures.

(2) If original clutch cover w ill be reinsta lled, ma rk

posit ion of cover on flyw heel for a ssembly reference

(Fig. 3). Use paint or a scriber for this purpose.

(3) L oose n cover bolt s e ven ly a n d in r ot a t ion t o

r e lieve sp rin g t e n sion e q u a lly. Th is is n e ce ssa r y t o

avoid warping cover.

(4) Remove cover bolts and remove cover and disc

(Fig. 4).

INSTALLATION

(1) L ig h t ly scu f f sa n d f ly w h e e l f a ce w it h 180 g r i t

em er y cl ot h . Th en cl ea n s ur fa ce w i t h a w a x a n d

grease remover.

(2) Lubricate pilot bearing with Mopar h ig h t e m -

perature bearing grease.

(3) Check new clutch for runout a nd free opera tion

on input shaft splines.(4) P osit ion clutch disc on flywheel. B e sure side of

d isc m a r k e d f ly w h e el sid e is p osit ion e d a g a in st f ly-

wheel (Fig. 4). I f disc is not marked, be sure flat side

o f d isc h u b is t o w a r d f ly w h e e l .

(5) I n sp ect con d it ion of p r essu r e p la t e su r f a ce of

clutch cover (Fig. 4). Replace cover if this surface is

worn, heat checked, cracked, or scored.

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

5).

(7) Insert alignment tool in pilot bearing and posi-

t ion d isc o n f ly w h e el . B e su r e d isc h u b is p osit ion e d

co r r e ct ly . S id e o f h u b m a r k e d F ly w h e e l S id e sh o u ld

face flywheel (Fig. 4). I f disc is not ma rked, place flat

sid e o f d isc a g a in st f lyw h e e l.

(8) Posit ion clutch cover over disc and on flywheel

(Fig. 5).

(9) Install clutch cover bolts finger t ight .

(10) Tighten cover bolts evenly an d in rotation a

f e w t h r e a d s a t a t im e . C o ve r bo lt s m u st be t ig h t e n e d

e ve nl y a n d t o s pe ci fi ed t or q u e t o a v oi d d i st or t i ng

cover. Tightening torques are 31 Nm (23 ft . lbs.) on

2.5L engines and 54 Nm (40 ft. lbs.) on 4.0L engines.

Fig. 3 Typical Method Of Marking Clutch CoverPosition

CLUTCH COVERPUNCH MARKSFLYWHEEL

XJ CLUTCH 6 - 1 1



12/16

(11) Apply light coat of Mopar h ig h t e m p e r a t u r e

b ea r i n g g r ea s e t o p il ot b ea r i n g h u b a n d s pl in es of

t r a n sm ission in pu t sh a f t . D o n o t over lu br ica t e sh a f tsp lin es. Th is w il l r e su lt in g r ea se con t a m in a t ion of

disc.

(12) I n s t a l l t r a n s m i ss ion (F i g. 6) a n d (F i g. 7).

Refer to G roup 21, Tran smission an d Tra nsfer Ca se,

for proper procedures.

CLUTCH HOUSING REPLACEMENT AX15

REMOVAL

(1) Raise vehicle and support vehicle.

(2) R em ov e t r a n s m is s ion a n d cl ut ch h ou s in g a s

a s s em b ly. R ef er t o G r o up 21, Tr a n s m is s ion a n d

Tra nsfer Ca se, for proper procedures.

(3) Remove release bearing, release fork, and fork

boot from input shaft and clutch housing.

(4) Remove bolts a t t aching clutch housing to tra ns-

mission (Fig. 8).

INSTALLATION

(1) C le a n m ou n t in g su r f a ce s of t r a n sm ission a n d

cl ut ch h ou s in g . U s e a w i r e b r u s h i f n ece ss a r y f ol -

low e d by a w a x a n d g r ea se r e m ove r, o r sim ila r sol-

vent. Also clean engine block surface as well.

(2) Po sit ion clu t ch h ou sin g on t r a n sm ission a n d

in st a l l h ou sin g a t t a ch in g bolt s . Tig h t en bolt s t o 38

Nm (28 ft . lbs.) torque.

(3) Insta ll release fork pivot ball st ud t o housing, if

necessary.

Fig. 6 Manual Transmission Mounting4.0L

ENGINE (4.0L) TRANSFER CASE VENTTUBECLUTCHHOUSING BRACKETITEM

TORQUE

Fig. 4 Clutch Disc And Pressure Plate Inspection

DISC INSPECT THISSURFACE CLUTCH COVERF LYW HEEL SI DE STAMPED ON THIS SUR-FACE

Fig. 5 Typical Method Of Aligning Clutch Disc

FLYWHEEL CLUTCH COVER AND DISCCLUTCH DISC ALIGNMENTTOOL

6 - 1 2 CLUTCH XJ

REMOVAL AND INSTALLATION (Continued)


13/16

(4) L u br ica t e r e le a se bea r in g bor e , r e le a se f or k

con t a c t s u r fa c es , a n d r el ea s e f or k p iv ot s t u d w i t h

Mopar high temperature bearing grease. Also lubri-

ca t e t r a n sm issio n in p u t sh a f t sp lin e s, p i lo t h u b a n d

bea r in g r e t a in er sl id e su r f a ce w it h l ig h t coa t of sa m e

grease.

(5) Install release fork, bearing, and boot in hous-

in g . B e su r e r e lea se f or k boot is p r op er ly se a t e d in

housing.

(6) I nsta ll tra nsmission. R efer to G roup 21, Tran s-

mission and Tran sfer C ase, for proper procedures.

RELEASE BEARING

REMOVAL

(1) R em ov e t r a n sm is si on . R ef er t o G r ou p 21,

Tra nsmission and Tran sfer Ca se, for proper proce-

dures.

(2) D i scon n ect r el ea s e b ea r i ng f rom f or k a n d

remove bearing (Fig. 9).

Fig. 7 Manual Transmission Mounting2.5L

TORQUEITEM

ENGINE (2.5L) CLUTCHHOUSINGCOVER BRACKETFWD

Fig. 8 Clutch Housing Attachment

HOUSING TO-TRANSMISSIONBOLTS (38 Nm/28ft. lbs.) CLUTCHHOUSING TRANSMISSION

Fig. 9 Release Bearing And Release Fork Mounting

CONED WASHER CLUTCH HOUSINGRELEASE FORKRELEASE BEARING ANDSLEEVEPIVOT 23 Nm (200IN. LBS.) SPRING

XJ CLUTCH 6 - 1 3



14/16

INSTALLATION

(1) I n sp ect r e le a se bea r in g sl id e su r f a ce of t r a n s-

m ission f r on t bea r in g r e t a in er. Re pla ce r e t a in e r i f

slide surface is scored, worn or cracked.

(2) Inspect release fork and fork pivot (Fig. 9). Be

su r e p ivot is se cu r e a n d in g ood con d it ion . B e su r e

f or k is n ot d ist or t e d or w o r n . Re p la ce r e le a se f or kr e t a in e r sp r in g i f be n t o r d a m a g e d in a n y w a y .

(3) L i gh t l y l ub r ica t e p il ot b ea r i n g, i n pu t s h a f t

splines, bearing retainer slide surface, fork pivot and

release fork pivot surface with Mopar high temper-

a t u r e be a r in g g r e a se .

(4) I n st a l l r e le a se f o r k a n d be a r in g . B e su r e f o r k

and bearing are properly secured.

(5) I nsta ll tra nsmission. R efer t o G roup 21, Tra ns-

mission an d Tra nsfer C ase, for proper procedures.

PILOT BEARING

REMOVAL(1) R em ov e t r a n sm is si on . R ef er t o G r ou p 21,

Tran smission an d Tra nsfer Ca se, for proper proce-

dures.

(2) Remove clutch cover and disc.

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

bearing.

INSTALLATION

(1) C le a n be a r in g bo r e w it h so lve n t a n d w ip e d r y

w it h sh op t ow e l .

(2) L u br ica t e n e w p ilo t be a r in g w it h Mo p a r high

temperature grease.

(3) Po sit io n a n d st a r t n e w be a r in g in be a r in g bo r eby h a n d . N o t e t h a t p i lo t be a r in g h a s se a l a t o n e e n d .

I n st a l l b ea r i ng s o s e a l i s f a ci ng ou t w a r d t ow a r d

transmission.

(4) S ea t p ilot bea r in g w it h clu t ch a l ig n m en t t o ol

(F ig . 10). K e ep bea r in g st r a ig h t d u r in g in st a l la t ion .

Do not allow bearing to become cocked. Tap bearing

in t o p la ce u n t i l f lu sh w it h e d g e o f be a r in g bo r e . D o

not recess bearing.

(5) Insta ll tra nsmission. R efer t o G roup 21, Tran s-

mission an d Tra nsfer C ase, for proper procedures.

CLUTCH HYDRAULIC LINKAGE

The clutch master cylinder, slave cylinder and con-n e ct in g l ine a r e ser vice d a s a n a sse m bly on ly. Th e

linkage components cannot be overhauled or serviced

s ep a r a t e ly. Th e cy l in d er s a n d con n ect i n g l in e a r e

sealed un its. Also note tha t removal/insta llat ion pro-

cedures for r ight and left hand drive models are basi-

ca l ly t h e s a m e. O nl y m a s t er cy li nd er l oca t i on i s

different.

REMOVAL

(1) Raise vehicle.

(2) Re m ove f a st e n er s a t t a ch in g sla ve cy l in d e r t o

clutch housing.

(3) R em ov e s l a v e cy li n de r f r om cl ut ch h ou s in g

(Fig. 11).

(4) Disengage clutch fluid line from body clips.

(5) Lower vehicle.

(6) Verify tha t cap on clutch ma ster cylinder reser-

vo ir is t ig h t . T h is is n e ce ssa r y t o a vo id u n d u e sp il l-

a g e d u r in g r e m ova l .

(7) Re m ove clu t ch m a st e r cy lin d er a t t a ch in g n u t s.

Note that both nuts are accessible from under instru-

ment panel (Fig. 12) and (Fig. 13).

(8) Remove clutch ma ster cylinder push rod from

pedal.

(9) Disconnect clutch pedal posit ion switch wires.

(10) If pedal pin is equipped with bushing, inspect

co n d it io n o f bu sh in g a n d r e p la ce i t i f w o r n o r d a m -

a g e d .

(11) R em ov e cl ut ch h y d ra u l ic l in k a g e t h r ou g h

engine compartment.

INSTALLATION

(1) Be sure reservoir cover on clutch master cylin-

d e r is t ig h t t o a void sp ills .

(2) P osit ion clutch linkage components in vehicle.

Wor k con n e ct in g l in e a n d sla ve cy lin d er d ow n w a r d

p a st e n gin e a n d a d ja cen t t o clu t ch h ou sin g.

(3) Posit ion clutch master cylinder on dash panel.

(4) At t a ch cl ut ch m a s t er cy li nd er pu sh r od t o

clutch pedal pin.

Fig. 10 Typical Method Of Installing Pilot Bearing

PILOT BEARINGALIGNMENT TOOLBEARING SEALMUST FACETRANSMISSIONKEEP BEARING STRAIGHT DUR-ING INSTALLATION TO AVOIDDAMAGE

6 - 1 4 CLUTCH XJ



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(5) I n st a l l a n d t i gh t en cl ut ch m a s t er cy li nd er

attaching nuts to 23-34 Nm (200-300 in. lbs.) torque.

(6) Raise vehicle.

(7) I n se r t s la ve cyl in de r p u sh r od t h r o ug h clu t ch

h o u sin g o p e n in g a n d in t o r e le a se le ve r . B e su r e ca p

on end of rod is securely engaged in lever. C heck t his

before installing cylinder at taching nuts.

(8) I n s t a l l a n d t i gh t en s la v e cy li n de r a t t a ch i ng

nuts to 23-34 Nm (200-300 in. lbs.) torque.

(9) Secure clutch fluid line in body clips.(10) Lower vehicle.

(11) Connect clutch pedal posit ion switch wires.

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUE

B olts, clutch cover 2.5 L . . . . . . . 31 Nm (23 ft . lbs)

B olts, clutch cover 4.0 L . . . . . . . 52 Nm (38 ft . lbs)

B olt/Nut, clutch cyl. mount . . . . 23 Nm (200 in. lbs)

B olt , clutch housing M12 . . . . . . . 75 Nm (55 ft . lbs)

B olt, clutch housing 3/8 . . . . . . . . 37 Nm (27 ft. lbs)B olt, clutch housing 7/16 . . . . . . . 58 Nm (43 ft. lbs)

B olt, clutch housing/tra ns. . . . . . . 38 Nm (28 ft. lbs)

B olt , dust shield M8 . . . . . . . . . . . 8 Nm (72 in. lbs)

B olt , dust shield lower . . . . . . . . . 50 Nm (37 ft . lbs)

B olt, X-member/fra me . . . . . . . . . 41 Nm (30 ft. lbs)

B olt, X-member/rea r support . . . 45 Nm (33 ft. lbs.)

B olts, f lywheel 4.0 L . . . . . . . . 142 Nm (105 ft . lbs)

B olts, flywh eel 2.5 L . . 68 Nm (50 ft. lbs) + 1/4 turn

B olt , st art er motor . . . . . . . . . . . . 45 Nm (33 ft . lbs)

B olts, U -joints . . . . . . . . . . . . . 19 Nm (170 in. lbs.)

Fig. 11 Slave Cylinder Attachment

CLUTCHHOUSINGSLAVE CYLIN-DER STUDS (2)CYLINDER FLUID LINEFWD

Fig. 12 Clutch Master Cylinder And Push RodAttachmentLeft Hand Drive Models

DASH PANEL PUSH RODCLUTCH MASTER CYLINDER

Fig. 13 Clutch Master Cylinder LocationRight

Hand Drive Models

XJ CLUTCH 6 - 1 5



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EXJ_699 jeep xj service manual

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