exj 6a, JEEP Manuals, Electronic Service Manual (jeep cherokee xj do 2000)
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XJ
CLUTCH
6 - 1
CLUTCH
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
REMOVAL AND INSTALLATION
SPECIFICATIONS
SPECIAL TOOLS
DESCRIPTION AND OPERATION
CLUTCH COMPONENTS
The clutch mechanism consists of a single, dry-type
clutch disc and a diaphragm style clutch cover. A
hydraulic linkage is used to operate the clutch disc
and cover. The clutch components are very similar to
those used in gas engine models.
A pilot bearing is used to support the transmission
input shaft. The bearing is seated in a separate,
removable housing bolted to the flywheel hub.
CLUTCH HYDRAULIC SYSTEM
The
clutch
hydraulic
system
should
not
require
additional fluid under normal circumstances.
NOTE: The reservoir fluid level will actually
increase as normal clutch wear occurs. For this rea-
son, it is important to avoid over filling, or remov-
ing fluid from the reservoir.
If inspection indicates additional fluid is needed,
add fluid from a sealed container only. Use Mopar
Fig. 1 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS
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brake fluid, or an equivalent meeting standards SAE
J1703 and DOT 3. Do not use any other type of fluid.
REMOVAL AND INSTALLATION
CLUTCH COVER AND DISC
a star pattern to relieve spring tension equally. This
is necessary to avoid warping the cover.
(4) Remove
REMOVAL
(1) Remove the transmission. Refer to Group 21,
Transmission and Transfer Case for procedure.
(2) If the original clutch cover will be reinstalled,
mark position of cover on flywheel for assembly ref-
erence. Use paint or scribe for this purpose.
(3) If the 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 in
the
clutch
cover
bolts
and
remove
cover and disc (Fig. 1).
INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth. Then clean surface with brake cleaner.
(2) Lightly lubricate the pilot bearing with Mopar
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high temperature bearing grease.
6 - 2
CLUTCH
XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 2 Clutch Components (VM Diesel)
1 – ENGINE BLOCK
2 – FLYWHEEL
3 – CLUTCH HOUSING AND TRANSMISSION
4 – CLUTCH COVER
5 – CLUTCH DISC
(3) Check free operation of clutch disc by sliding
disc
onto
transmission
output
shaft
splines.
Disc
should slide onto splines freely without binding.
(4) Position the clutch disc on flywheel. Be sure
side of disc marked “flywheel side” is positioned
against flywheel (Fig. 3). If disc is not marked, be
sure flat side of disc hub is placed toward the fly-
wheel.
(5) Insert
the
clutch
alignment
tool
(Fig.
4)
in
clutch disc and pilot bearing.
(6) Position the clutch cover over the disc and on
the flywheel (Fig. 5).
(7) Install the clutch cover bolts finger tight (Fig.
5).
(8) Starting with the bolts marked “P” on the cover
first, tighten clutch cover bolts in a star pattern to 50
N·m torque (37 ft. lbs.).
(9) Apply light coat of Mopar
high temperature
bearing grease to pilot bearing and splines of trans-
mission input shaft.
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Fig. 3 Clutch Disc Position
1 – INSPECT THIS SURFACE
2 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE
CAUTION: Do not over-lubricate as this will result
in grease contamination of the disc.
XJ
CLUTCH
6 - 3
REMOVAL AND INSTALLATION (Continued)
PILOT BEARING
REMOVAL
(1) Remove the transmission and transfer case.
Refer to Group 21, Transmission and Transfer Case
for procedures.
Fig. 4 Clutch Disc Alignment – Typical
1 – FLYWHEEL
2 – CLUTCH COVER AND DISC
3 – CLUTCH DISC ALIGNMENT TOOL
Fig. 6 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS
(2) Remove the clutch cover and disc (Fig. 6). Refer
to clutch cover and disc removal and installation in
this group.
(3) Remove
the
four
bolts
that
attach
the
pilot
bearing retainer to the flywheel (Fig. 7).
(4) Remove the pilot bearing retainer.
(5) Support
the
bearing
retainer
on
two
wood
Fig. 5 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS
blocks.
(6) Remove the pilot bearing with a suitable sized
socket and extension (Fig. 8). Use mallet to tap bear-
ing out of retainer.
(10) Install the transmission and transfer case.
Refer to Group 21, Transmission and Transfer Case
for procedure.
6 - 4
CLUTCH
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REMOVAL AND INSTALLATION (Continued)
Fig. 9 Pilot Bearing Installation
1 – HOUSING
2 – SPECIAL TOOL C-4171
3 – BEARING
Fig. 7 Pilot Bearing Retainer Bolt Removal/
Installation
1 – RETAINER
2 – PILOT BEARING
3 – FLYWHEEL
Fig. 10 Pilot Bearing Seated In Retainer
1 – SEAT PILOT BEARING FLUSH WITH LOWER EDGE OF
CHAMFER (IN BORE)
Fig. 8 Pilot Bearing Removal
1 – HOUSING
2 – SUITABLE SIZE SOCKET
3 – EXTENSION
(1) Lightly scuff sand the flywheel surface with
180 grit emery cloth. Clean the surface with Mopar
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brake or carburetor cleaner.
(2) Install the new pilot bearing with hammer and
tool handle C-4171. (Fig. 9). Seat the bearing flush
with lower edge of chamfer in retainer bore (Fig. 10).
Reposition the bearing if necessary.
(3) Install the bearing retainer. Torque bolts to 28
N·m (20 ft. lbs.)
(4) Lubricate the pilot bearing with Mopar
INSTALLATION
CAUTION: The bearing can be installed incorrectly
if care is not exercised. Make sure the stamped let-
ters on the bearing will be facing out (toward rear
of vehicle) after installation.
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high
temperature wheel bearing grease.
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CLUTCH
6 - 5
REMOVAL AND INSTALLATION (Continued)
Fig. 11 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS
Fig. 12 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS
INSPECTION
Examine the flywheel mounting surfaces, clutch
contact surface, and ring gear. Check condition of fly-
wheel hub and attaching bolts. Replace flywheel if
hub exhibits cracks in the area of attaching bolt
holes. Replace ring gear if the teeth are damaged.
Resurface the flywheel if the clutch contact surface is
scored or rough (refer to flywheel finishing and ring
gear replacement information in this section.
Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm. Measure
flywheel face runout with a dial indicator (Fig. 13).
Mount the indicator on a stud installed in the engine
block or in one of the flywheel attaching bolt holes.
Face runout can be corrected by resurfacing if neces-
sary. Surface grinding equipment is recommended for
this purpose. Stock removal should not exceed 0.25
mm.
(5) Install the clutch disc and cover (Fig. 11). Refer
to clutch cover and disc removal and installation in
this group.
(6) Install the transmission and transfer case.
Refer to Group 21, Transmission and Transfer Case
for procedures.
FLYWHEEL
REMOVAL
(1) Remove the transmission and clutch housing.
Refer to Group 21, Transmission and Transfer Case
for procedure.
(2) Remove the clutch cover and disc (Fig. 12) as
described in this section.
(3) Remove
the
bolts
that
attach
pilot
bearing
retainer to flywheel.
(4) Remove the pilot bearing and retainer.
(5) Remove the flywheel bolts.
(6) Grasp the flywheel firmly and work it off the
crankshaft flange.
(7) Remove the o-ring from the crankshaft flange,
or the mounting shoulder of the flywheel (Fig. 14).
(8) Clean the flywheel in solvent.
INSTALLATION
CAUTION: Use NEW flywheel bolts for the following
procedure.
(1) Clean the crankshaft flange before mounting
the flywheel. Dirt or grease on flange surface may
cock flywheel causing run-out.
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