1988 JEEP CHEROKEE clutch
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Information pertaining to Sanden compressors in this article,
will be found in earlier articles under Sankyo compressors.
AMERICAN MOTORS & JEEP WITH 5-CYLINDER COMPRESSOR
Compressor Overhaul
1) After the compressor and system have been run, stop the
engine. Slowly discharge system using approved refrigerant
recovery/recycling equipment. Clean and cool dipstick with R-12.
2) Loosen the compressor mounting bolts, remove the drive
belt, and move the compressor to a bench for easiest and most accurate
measurement. Position the compressor so that the oil fill plug is at
top dead center.
3) Thoroughly clean the oil fill plug and the area around it.
Loosen the fill plug slowly to allow trapped refrigerant pressure to
escape through the loosened threads.
4) The front plate hub has a lobe, which is indexed (notched)\
180
from TDC of the cam rotor. Rotate the hub plate lobe until the
index notch is 110 from bottom center. See Fig. 1. Check this
position by looking through the oil fill hole and noting that the ball
end of the top piston rod lines up with the fill hole.
5) Looking at the front end of the compressor, insert the
dipstick diagonally from upper left to lower left until the dipstick
stop contacts the filler hole surface. Remove dipstick and note oil
level. Oil level should be between the 4th and 6th increment on the
dipstick (3-4 ounces). Add oil as necessary.
Compressor Replacement
If system was opened by a leak or so quickly that oil was
lost, install new compressor with all the oil it contains. If system
was opened slowly and oil was not lost, drain oil from new compressor
and measure. Reinstall 6 ounces of oil back into new compressor prior
to installation.
Component Replacement
If a hose, receiver-drier, condenser, expansion valve or
evaporator core requires replacement, add 1 ounce of new oil for each
new component installed.
Compressor Oil Check
1) Discharge system, using approved refrigerant
recovery/recycling equipment, or isolate compressor. Remove oil filler
plug. Look through oil filler plug hole and rotate clutch front plate
to position piston connecting rod in center of oil filler plug hole.
2) Insert dipstick (J-29642-12) through oil filler plug hole\
to the right of piston connecting rod until dipstick stop contacts the
compressor housing.
3) Remove dipstick and count number of increments covered
with oil. If compressor is properly filled, oil will cover 4-6
increments on the dipstick. Adjust oil level as necessary.
Page 174 of 1378
![JEEP CHEROKEE 1988 Service Repair Manual Tiny bubbles in sight
glass. Discharge air warm
when low side gauge drops
into vacuum.
\](/manual-img/16/57037/w960_57037-173.png "JEEP CHEROKEE 1988 Service Repair Manual Tiny bubbles in sight
glass. Discharge air warm
when low side gauge drops
into vacuum.
\")
Tiny bubbles in sight
glass. Discharge air warm
when low side gauge drops
into vacuum.
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Normal Normal Thermostatic switch system Defective Thermo-
only-compressor cycles off static Switch
and on too rapidly.
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Normal Normal Cycling clutch systems Misadjusted Thermo
to High only-Compressor doesn't static Switch or
turn on soon enough. Defective Pressure
Discharge air becomes Sensing Switch
warm as low side
pressure rises.
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Low Low Bubbles in sight glass. Low R-12 Charge
Outlet air slightly cool.
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Low Low Sight glass clear or oil- Excessively Low
streaked. Outlet air very R-12 Charge
warm.
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Low Low Outlet air slightly cool. Expansion Valve
Sweating or frost at Stuck Closed.
expansion valve. Screen Plugged or
Sensing Bulb
Malfunction
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Low Low Outlet air slightly cool. Restriction on
High side line cool to High Side.
touch. Sweating or frost
on high side.
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Low High Evaporator outlet pipe STV Stuck Open
cold. Low side goes into
vacuum when blower is
disconnected.
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High Low Evaporator outlet pipe STV Stuck Open
warm. Outlet air warm.
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High Low Noise from compressor Compressor
Malfunction
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High High Outlet air warm. Condenser
Liquid line very hot. Malfunction or
Bubbles in sight glass. R-12 Overcharge
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High High Outlet air slightly cool. Large Amount of
Bubbles in sight glass. Air and Moisture
in System.
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High High Outlet air warm. Expansion Valve
Evaporator outlet Stuck Open.
sweating and frost.
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(1) - If equipped with a low refrigerant charge protection system,
compressor operation may have stopped.
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A/C SYSTEM SERVICE SPECIFICATIONS
Page 327 of 1378
Clean hub and rotor mating surfaces. To install, reverse
removal procedure.
NOTE: DO NOT disconnect brake hose from caliper unless caliper is
to be disassembled.
DISC BRAKE ROTOR - CHEROKEE, COMANCHE & WAGONEER
Removal
1) Raise and support vehicle. Remove front wheel and caliper.
Suspend caliper from frame or suspension. Remove cap, cotter pin, nut
retainer, adjusting nut and thrust washer from spindle.
2) Remove outer bearing from hub. Remove hub and rotor from
spindle. Remove hub and rotor seal. Remove inner bearing from hub.
Installation
1) Apply small amount of "EP" type waterproof wheel bearing
grease in hub cavity. Lubricate inner and outer bearings. Install
inner bearing and seal in rotor. Clean rotor surface (if necessary).
2) Install hub and rotor on spindle. Install outer bearing,
thrust washer and spindle nut. Tighten spindle nut to 17-25 ft. lbs.
(23-34 N.m) while rotating rotor to seat bearings. Loosen spindle nut
1/2 a turn and retighten an additional 19 INCH lbs (2 N.m). Reverse
removal procedure to complete installation.
DISC BRAKE ROTOR - GRAND WAGONEER
Removal
1) Raise vehicle and support with safety stands. Remove wheel
and caliper. On models without front hubs, remove rotor hub cap, drive
gear snap ring, drive gear, pressure spring and spring cup.
2) On models with front hubs, remove screws attaching hub
body to hub clutch and remove hub body from clutch. Remove large and
small retaining rings. Remove hub clutch from axle shaft.
3) On all models, remove wheel bearing outer and inner lock
nuts and retaining ring using Socket (J-6893-D). Remove rotor. Remove
wheel bearings from rotor.
Installation
1) Lubricate bearings with "EP" type waterproof wheel bearing
grease. Install bearings and seal in rotor. Install rotor and inner
lock nut. Inner lock nut has a locating peg on one side. When
installed, peg must face away from bearing.
2) Install wheel, but do not tighten lug nuts completely.
Tighten inner lock nut to 50 ft. lbs. (68 N.m) while rotating wheel.
Back of inner lock nut 1/6 turn (45-65 degrees).
3) Install retaining washer. Ensure that inner lock nut
locating peg is engaged with retaining washer. Install outer lock nut
and tighten to 50 ft. lbs. (68 N.m).
4) On models without front hubs, install pressure spring cup,
pressure spring, drive gear and snap ring. Coat rim of chrome hub
cover with Permatex No. 3 and install cap in rotor hub.
NOTE: Recessed side of spring cup faces outer bearing and flat
side faces pressure spring.
5) On models with front hubs, install hub clutch on axle.
Install large and small hub retaining rings. Install hub body on
clutch and tighten to 30 INCH lbs. (3 N.m). Reverse removal procedure
to complete installation.
DRUM BRAKE SHOES - EXCEPT GRAND WAGONEER
Page 340 of 1378
CLU TC H
1988 J e ep C hero ke e
1988 Clutch
Hydraulic
Cherokee, Comanche, Wagoneer, Wrangler
DESCRIPTION
The clutch assembly consists of a single dry-disc driven
plate and a one-piece diaphragm spring-type clutch cover. On Wrangler
4-cylinder models, the clutch cover and driven plate diameter is 9.28"
(232 mm). On Wrangler 6-cylinder models, the clutch cover and driven
plate diameter is 10.5" (266 mm). On all other 4 and 6-cylinder
models, the clutch cover and driven plate diameter is 9.7"
(246 mm). The clutch is actuated through a hydraulic master cylinder
and slave cylinder.
On Wrangler models, the slave cylinder is mounted inside the
clutch housing. The bearing is permanently attached to the cylinder
piston.
TRANSMISSION APPLICATION
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Vehicle Model Transmission Model
Cherokee, Comanche, Wagoneer ........... Aisin AX4 4-Speed
Aisin AX5 5-Speed O/D
Wrangler ........................... Aisin AX5 5-Speed O/D
Peugeot BA 10/5 5-Speed O/D
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REMOVAL & INSTALLATION
TRANSMISSION
Removal
1) Remove the shift knob and lock nut from transmission and
transfer case shift levers (if equipped). On Wrangler models, remove
screws attaching transmission and transfer case shift lever boots and
remove both boots.
2) On all other models, raise outer gearshift lever boot and
remove upper part on center console. Remove lower part of console,
remove inner boot and gearshift lever.
3) On Wrangler models, remove transmission shift tower dust
cover. Remove transmission shift lever and stub shaft. DO NOT remove
shift lever from stub shaft.
4) On all models, raise and support vehicle. Drain
transmission lubricant. Mark rear drive shaft for reassembly and
remove rear drive shaft. Support transmission assembly and remove
crossmember. Disconnect speedometer cable and wiring from back-up
light switch.
5) On 4WD models, drain transfer case lubricant. Disconnect
transfer case vacuum hoses and linkage. Tag vacuum hoses for
reassembly. Disconnect front drive shaft and secure out of way.
6) On all models, remove clutch slave cylinder. Position
transmission jack under transmission assembly. Remove bolts securing
clutch housing to engine and remove transmission assembly. Remove
throw-out lever, bearing, and pivot ball from clutch housing.
Installation
To install, reverse removal procedure.
Page 341 of 1378
CLUTCH
Removal
Remove transmission assembly. Mark position of clutch cover
on flywheel for reassembly reference. Evenly loosen clutch cover bolts
one or 2 turns at a time until clutch cover spring tension is
released. Remove cover bolts, clutch cover, and disc. See Fig. 1.
Installation
1) Check all components for wear or damage and replace as
necessary. Using clutch alignment tool, align clutch disc and loosely
install clutch cover. Be sure marks made during removal are aligned.
2) To avoid warping clutch cover, tighten each cover bolt a
few turns at a time. To complete installation, reverse removal
procedure.
Fig. 1: Exploded View Of Cherokee, Comanche & Wagoneer Hydraulic
Clutch Assembly
Wrangler has a one-piece slave cylinder.
CLUTCH MASTER CYLINDER
Removal
1) Disconnect hydraulic line at master cylinder. Plug
openings to prevent dirt from entering system. Remove cotter pin and
washer holding cylinder push rod on clutch pedal.
2) Slide push rod off pedal pivot. Remove nuts attaching
clutch master cylinder to studs on dash panel and remove cylinder.
Installation
To install, reverse removal procedure. Bleed hydraulic
system.
Page 342 of 1378
CLUTCH SLAVE CYLINDER
Removal (Wrangler)
1) Disconnect slave cylinder inlet line. Remove transmission
and transfer case. Slide rubber insulator off slave cylinder lines.
Remove bolts attaching insulator bracket to clutch housing. Slide
bracket off cylinder lines.
2) Remove slave cylinder and bearing retaining nut. Pry nut
up and off mounting pin on transmission front case. Remove slave
cylinder and bearing by sliding assembly off transmission input shaft.
See Fig. 2 .
Installation
To install, reverse removal procedure. Bleed hydraulic
system.
Fig. 2: Wrangler Clutch Slave Cylinder
Courtesy of Chrysler Motors.
Removal (Cherokee, Comanche & Wagoneer)
Disconnect hydraulic line at clutch slave cylinder. Cap line
to prevent fluid loss. Remove spring holding clutch fork lever to
cylinder push rod. Remove bolts attaching slave cylinder to clutch
housing. Remove slave cylinder, heat shield, clutch fork pivot, washer
and seal.
Installation
To install, reverse removal procedure. Bleed hydraulic
system.
PILOT BUSHING
Page 343 of 1378
Removal (Cherokee, Comanche & Wagoneer)
Remove clutch assembly. Remove pilot bushing using Slide
Hammer (J-2619-01) and Bushing Remover (J-5822).
Installation
Lubricate replacement bushing with engine oil. Remove pilot
bushing lubricating wick and soak wick in engine oil. Install wick in
bushing bore. Install bushing using Clutch Pilot Shaft (J-33169). Keep\
pilot shaft parallel with crankshaft center line to prevent damage to
bushing. Reverse removal procedure to complete installation.
OVERHAUL
CLUTCH MASTER CYLINDER
Disassembly
1) Remove reservoir cap and cover. Remove push rod dust
cover. Remove snap ring holding push rod in cylinder bore. Discard
dust cover and snap ring.
2) Remove push rod, retaining washer, and seal as an
assembly. Discard seal. Remove plunger, valve spring, and valve stem
assembly from cylinder bore by tapping cylinder body on wood block.
3) Compress valve spring slightly. Pry tab of valve stem
retainer upward to release retainer, spring and stem assembly from
plunger. Remove seal from plunger and discard. Remove spring retainer
and valve stem from valve spring.
NOTE: Retainer tab is located in rectangular slot in side of stem
retainer.
4) Remove valve stem from retainer. Remove spring washer and
stem tip seal from end of valve stem. See Fig. 3. Discard stem tip
seal and spring washer. Clean parts with brake fluid or brake cleaning
solvent.
5) Inspect cylinder bore for wear, nicks or scores. Master
cylinder bore must be clean and smooth. Light discoloration is
acceptable. Replace if necessary. Clutch master cylinder must not be
honed under any circumstances.
Fig. 3: Exploded View Of Clutch Master Cylinder
Courtesy of Chrysler Motors.
Reassembly
1) Lubricate cylinder bore with brake fluid. Make sure lip of
Page 344 of 1378
plunger seal faces stem end of plunger. Install stem tip seal so seal
shoulder fits in undercut at end of valve stem.
2) End of valve stem should pass through stem retainer and
seat in small bore in end of plunger. Bend retainer tab downward to
lock stem and retainer on plunger. To complete assembly, reverse
disassembly procedures.
CLUTCH SLAVE CYLINDER
Disassembly
NOTE: On Wrangler models, the integral slave cylinder and throw
out bearing assembly is not serviceable. If cylinder,
bearing or lines become damaged the entire assembly must be
replaced.
1) Clean cylinder exterior. Remove dust boot from cylinder.
Remove cylinder push rod, plunger and spring as an assembly. Remove
spring seal from plunger.
2) Remove snap ring holding push rod in plunger. Remove push
rod and boot. Remove boot from push rod. See Fig. 4. Clean parts with
brake fluid or brake cleaning solvent. Inspect cylinder bore for wear,
nicks or scores. Replace if necessary.
Fig. 4: Exploded View Of Clutch Slave Cylinder
Courtesy of Chrysler Motors.
Reassembly
Reverse disassembly procedure. Lubricate cylinder bore and
seal with brake fluid before reassembly.
HYDRAULIC SYSTEM BLEEDING
1) Fill master cylinder reservoir with DOT 3 brake fluid. On
all models except Wrangler, compress slave cylinder plunger by pushing
release lever as far forward as possible.
2) Attach rubber hose to slave cylinder bleeder screw.
Immerse other end of hose in glass container 1/2 full of brake fluid.
Loosen bleeder screw and have an assistant depress clutch pedal.
Tighten bleeder screw and release pedal.
3) Repeat bleeding procedure until fluid entering container
is free of bubbles. DO NOT allow reservoir to run out of fluid during