1994 JEEP CHEROKEE transmission

when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing. To avoid warping the cover, the bolts must tight-
ened alternately (diagonal pattern) and evenly (2-3
threads at a time) to specified torque.
Clutch Housing Misalignment
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment
between the crankshaft and transmission input shaft.
Misalignment can cause clutch noise, hard shifting,
incomplete release and chatter. It can also result in
premature wear of the pilot bearing, cover release
fingers and clutch disc. In severe cases, misalign-
ment can also cause premature wear of the transmis-
sion input shaft and shaft bearing.
Housing misalignment is generally caused by in-
correct seating on the engine or transmission, loose
housing bolts, missing alignment dowels or housing
damage. Infrequently, misalignment may also be
caused by housing mounting surfaces that are not
completely parallel. Misalignment can be corrected
with shims.INSTALLATION METHODS AND PARTS
USAGE
Distortion of clutch components during installation
and the use of non-standard components are addi-
tional causes of clutch malfunction.
Improper clutch cover bolt tightening can distort
the cover. The usual result is clutch grab, chatter
and rapid wear. Tighten the cover bolts as described
in Clutch Service section.
An improperly seated flywheel and/or clutch hous-
ing are additional causes of clutch failure. Improper
seating will produce misalignment and additional
clutch problems.
The use of non-standard or low quality parts will
also lead to problems and wear. Use recommended
factory quality parts to avoid comebacks.
INSPECTION AND DIAGNOSIS CHARTS
The clutch inspection chart (Fig. 1) outlines items
to be checked before and during clutch installation.
Use the chart as a check list to help avoid overlook-
ing potential problem sources during service opera-
tions.
The diagnosis charts describe common clutch prob-
lems, causes and correction. Fault conditions are
listed at the top of each chart. Conditions, causes and
corrective action are outlined in the indicated col-
umns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
6 - 4 CLUTCH DIAGNOSISJ

CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation............ 10
Clutch Cover and Disc Removal............. 10
Clutch Fluid Level........................ 14
Clutch Housing Replacement................ 11
Clutch Hydraulic Linkage Installation.......... 12
Clutch Hydraulic Linkage Removal........... 11Clutch Pedal Installation................... 15
Clutch Pedal Removal..................... 15
Clutch Safety Precautions.................. 10
Flywheel Service......................... 15
Pilot Bearing Replacement................. 11
Release Bearing Replacement............... 11
CLUTCH SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. DUST AND DIRT ON
CLUTCH PARTS USE MAY CONTAIN ASBESTOS FI-
BERS. BREATHING EXCESSIVE CONCENTRATIONS
OF THESE FIBERS CAN CAUSE SERIOUS BODILY
HARM. WEAR A RESPIRATOR DURING SERVICE
AND NEVER CLEAN CLUTCH COMPONENTS WITH
COMPRESSED AIR OR WITH A DRY BRUSH. EI-
THER CLEAN THE COMPONENTS WITH A WATER
DAMPENED RAGS OR USE A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR REMOVING ASBES-
TOS FIBERS AND DUST. DO NOT CREATE DUST
BY SANDING A CLUTCH DISC. REPLACE THE DISC
IF THE FRICTION MATERIAL IS DAMAGED OR
CONTAMINATED. DISPOSE OF ALL DUST AND
DIRT CONTAINING ASBESTOS FIBERS IN SEALED
BAGS OR CONTAINERS. THIS WILL HELP MINIMIZE
EXPOSURE TO YOURSELF AND TO OTHERS. FOL-
LOW ALL RECOMMENDED SAFETY PRACTICES
PRESCRIBED BY THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION (OSHA) AND THE
ENVIRONMENTAL SAFETY AGENCY (EPA), FOR
THE HANDLING AND DISPOSAL OF PRODUCTS
CONTAINING ASBESTOS.
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 ref-
erence. 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 avoid warping cover.
(4) Remove cover bolts and remove cover and disc
(Fig. 2).
CLUTCH COVER AND DISC 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 tem-
perature 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 fly-
wheel (Fig. 2). If disc is not marked, be sure flat side
of disc hub is toward flywheel.
(5) Insert clutch alignment tool in clutch disc (Fig.
3).
(6) Insert alignment tool in pilot bearing and posi-
tion disc on flywheel. Be sure disc hub is positioned
correctly. Side of hub marked Flywheel Side should
face flywheel (Fig. 2). If disc is not marked, place flat
side of disc against flywheel.
(7) Position clutch cover over disc and on flywheel
(Fig. 3).
(8) Install clutch cover bolts finger tight.
(9) Tighten cover bolts evenly and in rotation a
few threads at a time.Cover bolts must be tight-
ened evenly and to specified torque to avoid dis-
torting cover. Tightening torques are 31 Nzm (23
ft. lbs.) on 2.5L engines and 54 Nzm (40 ft. lbs.) on
4.0L engines.
(10) Apply light coat of Mopar high temperature
bearing grease to pilot bearing hub and splines of
transmission input shaft.Do not overlubricate
shaft splines. This will result in grease contami-
nation of disc.
(11) Install transmission (Fig. 4). Refer to proce-
dures in Group 21.
6 - 10 CLUTCH SERVICEJ

RELEASE BEARING REPLACEMENT
(1) Remove transmission as described in Group 21.
(2) Disconnect release bearing from release lever
and remove bearing (Fig. 5).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face 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 in any way.
(5) Lubricate crankshaft pilot bearing with Mopar
high temperature bearing grease. Apply grease to
end of long shank, small diameter flat blade screw-
driver. Then insert tool through clutch disc hub to
reach bearing.
(6) Lubricate input shaft splines, bearing retainer
slide surface, fork pivot and release fork pivot sur-face with Mopar high temperature grease.
(7) Install new release bearing. Be sure bearing is
properly secured to release fork.
(8) Install transmission as described in Group 21.
PILOT BEARING REPLACEMENT
(1) Remove transmission. Refer to Group 21 for
procedure.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use internal (blind hole)
puller such those as supplied in Snap On Tool Set
CG40CB to remove bearing.
(4) Lubricate new bearing with Mopar high tem-
perature bearing grease.
(5) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool (Fig.
6).
(6) Lightly scuff sand flywheel surface with 180
grit emery cloth. Then clean surface with wax and
grease remover.
(7) Install clutch disc and cover as described in
this section.
(8) Install transmission. Refer to Group 21 for pro-
cedure.
CLUTCH HOUSING REPLACEMENT
The AX 15 clutch housing is removable and can be
replaced when the transmission is out of the vehicle.
The bolts attaching the housing to the transmis-
sion case are located inside the housing (Fig. 7). Rec-
ommended tightening torque for the clutch housing-
to-transmission bolts is 38 Nzm (28 ft. lbs.).
Be sure the transmission and housing mating
surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign ma-
terial trapped between the housing and trans-
mission will cause misalignment. If
misalignment is severe enough, the result will be
clutch drag, incomplete release and hard shift-
ing.
CLUTCH HYDRAULIC LINKAGE REMOVAL
The clutch master cylinder, slave cylinder and
connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled 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.
(1) Raise vehicle.
(2) Remove fasteners attaching slave cylinder to
clutch housing.
(3) Remove slave cylinder from clutch housing
(Fig. 8).
(4) Disengage clutch fluid line from body clips.
(5) Lower vehicle.
Fig. 2 Clutch Disc Position
Fig. 3 Typical Method Of Aligning Clutch Disc
JCLUTCH SERVICE 6 - 11

(6) Verify that cap on clutch master cylinder reser-
voir is tight. This is necessary to avoid undue spill-
age during removal.
(7) Remove clutch master cylinder attaching nuts.
Note that one nut is accessible from engine compart-
ment and one nut is accessible from under instru-
ment panel (Figs. 9 and 10).
(8) Remove clip securing clutch master cylinder
push rod to pedal and slide push rod off pedal pin.
(9) If pedal pin is equipped with bushing, inspect
condition of bushing and replace it if worn or dam-
aged.
(10) Remove clutch hydraulic linkage through en-
gine compartment.
CLUTCH HYDRAULIC LINKAGE INSTALLATION
(1) Be sure reservoir cover on clutch master cylin-
der is tight to avoid spills.
Fig. 4 Manual Transmission Mounting
Fig. 5 Release Bearing Attachment
Fig. 6 Pilot Bearing Installation
6 - 12 CLUTCH SERVICEJ

COOLING SYSTEM
CONTENTS
page page
DIAGNOSIS............................. 4
ENGINE ACCESSORY DRIVE BELTS........ 31
ENGINE BLOCK HEATER................. 37GENERAL INFORMATION.................. 1
SERVICE PROCEDURES................... 9
SPECIFICATIONS....................... 38
GENERAL INFORMATION
Throughout this group, references are made to par-
ticular vehicle models by alphabetical designation
(XJ or YJ) or by the particular vehicle nameplate. A
chart showing a breakdown of alphabetical designa-
tions is included in the Introduction section at the
beginning of this manual.
COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible, maintains
normal operating temperature and prevents over-
heating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed heavy duty cooling
package is available on most models. The package
consists of a radiator that has an increased numberof cooling fins. XJ models equipped with a 4.0L 6 cyl-
inder engine and heavy duty cooling and/or air con-
ditioning also have an auxiliary electric cooling fan.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
²A radiator
²Cooling fan (mechanical and/or electrical)
²Thermal viscous fan drive
²Fan shroud
²Radiator pressure cap
²Thermostat
²Coolant reserve/overflow system
²Transmission oil cooler (if equipped with an auto-
matic transmission)
²Coolant
²Water pump
²Hoses and hose clamps
SYSTEM COOLANT ROUTING
For cooling system flow routings, refer to Figs. 1, 2,
3or4.
JCOOLING SYSTEM 7 - 1

SERVICE PROCEDURES
INDEX
page page
Coolant................................ 15
Coolant Reserve/Overflow System............ 19
Cooling System Cleaning/Reverse Flushing..... 17
Cooling System Fans..................... 26
Cooling System Hoses.................... 26
Draining Cooling System................... 16
Radiator Pressure Cap.................... 20
Radiators............................... 22Refilling Cooling System................... 17
Testing Cooling System for Leaks............ 18
Thermostat............................. 13
Transmission Oil Coolers................... 29
Water Pump Tests........................ 9
Water PumpsÐGeneral Information............ 9
Water PumpsÐRemoval/Installation........... 10
WATER PUMPSÐGENERAL INFORMATION
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a
drive belt on all engines.
The water pump impeller is pressed onto the rear
of a shaft that rotates in bearings pressed into the
housing. The housing has a small hole to allow seep-
age to escape. The water pump seals are lubricated
by the antifreeze in the coolant mixture. No addi-
tional lubrication is necessary.
CAUTION: All engines are equipped with a reverse
(counter-clockwise) rotating water pump and vis-
cous fan drive assembly. REVERSE is stamped or
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 1).Engines from previous model years, depending
upon application, may have been equipped with a
forward (clockwise) rotating water pump. Installation
of the wrong water pump will cause engine overheat-
ing.
A quick test to determine if the pump is working is
to check if the heater warms properly. A defective
water pump will not be able to circulate heated cool-
ant through the long heater hose to the heater core.
WATER PUMP TESTS
LOOSE IMPELLER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drain the cooling system.
(2) Loosen the fan belt(s).
(3) Disconnect the lower radiator hose from the
water pump.
(4) Bend a stiff clothes hanger or welding rod as
shown in (Fig. 2).
(5) Position the rod in the water pump inlet and
attempt to hold the impeller while turning the fan
blades. If equipped with a viscous fan drive, turn the
water pump shaft with a breaker bar and socket at-
tached to a mounting flange nut. If the impeller is
loose and can be held with the rod while the fan
blades are turning, the pump is defective. If the im-
peller turns, the pump is OK.
Connect the hose and install the coolant, or proceed
with repairs.
INSPECTING FOR INLET RESTRICTIONS
Inadequate heater performance may be caused by a
metal casting restriction in the water pump heater
hose inlet.Fig. 1 Reverse Rotating Water PumpÐTypical
JCOOLING SYSTEM 7 - 9

CAUTION: Tightening the thermostat housing un-
evenly or with the thermostat out of its recess, may
result in a cracked housing.
(3) Tighten the housing bolts to 20 Nzm (15 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant tempera-
ture sensor.
(6) Be sure that the radiator draincock is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture. Refer to Refilling
Cooling System in this group.
(7) Start and warm the engine. Check for leaks.
COOLANT
GENERAL INFORMATION
The cooling system is designed around the coolant.
Coolant flows through the engine water jackets ab-
sorbing heat produced during engine operation. The
coolant carries heat to the radiator and heater core.
Here it is transferred to the ambient air passing
through the radiator and heater core fins. The cool-
ant also removes heat from the automatic transmis-
sion fluid in vehicles equipped with an automatic
transmission.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion inhib-
iting additives in ethylene-glycol need the presence
of water to dissolve. Without water, additives form
deposits in system. These act as insulation causing
temperature to rise to as high as 149ÉC (300ÉF). This
temperature is hot enough to melt plastic and soften
solder. The increased temperature can result in en-
gine detonation. In addition, 100 percent ethylene-
glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-35ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION-ADDITIVES
Coolant should be maintained at the specified level
with a mixture of ethylene glycol-based antifreeze
and low mineral content water. Only use an anti-
freeze containing ALUGARD 340-2 Ÿ.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT SERVICE
It is recommended that the cooling system be
drained and flushed at 84,000 kilometers (52,500
miles), or 3 years, whichever occurs first. Then every
two years, or 48,000 kilometers (30,000 miles),
whichever occurs first.
COOLANT LEVEL CHECKÐROUTINE
Do not remove radiator cap for routine coolant
level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The coolant reserve/overflow system provides a
quick visual method for determining coolant level
without removing radiator pressure cap. With engine
idling and at normal operating temperature, observe
coolant level in reserve/overflow tank. The coolant
level should be between ADD and FULL marks.
Fig. 16 Thermostat Recess
JCOOLING SYSTEM 7 - 15

Leakage Test. Do this if it is certain that coolant is
being lost and no leaks can be detected.
²Drops Slowly: Shows a small leak or seepage is oc-
curring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect the radiator,
hoses, gasket edges and heater. Seal any small leak
holes with a Sealer Lubricant or equivalent. Repair
leak holes and reinspect the system with pressure
applied.
²Drops Quickly: Shows that a serious leakage is oc-
curring. Examine the system for serious external
leakage. If no leaks are visible, inspect for internal
leakage. Large radiator leak holes should be repaired
by a reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove the oil pan drain plug and drain a small
amount of engine oil. Coolant, being heavier will
drain first, or operate engine to churn oil, then ex-
amine dipstick for water globules. Inspect the trans-
mission dipstick for water globules. Inspect the
transmission fluid cooler for leakage. Operate the en-
gine without the pressure cap on the radiator until
thermostat opens.
Attach a Pressure Tester to the filler neck. If pres-
sure builds up quickly, a leak exists as result of a
faulty cylinder head gasket or crack in the engine.
Repair as necessary.
WARNING: DO NOT ALLOW PRESSURE TO EX-
CEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
If there is no immediate pressure increase, pump
the Pressure Tester until the indicated pressure is
within the system range. Vibration of the gauge
pointer indicates compression or combustion leakage
into the cooling system.WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
Isolate the compression leak by shorting each
spark plug to the cylinder block. The gauge pointer
should stop or decrease vibration when spark plug
for leaking cylinder is shorted. This happens because
of the absence of combustion pressure.
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Drain sufficient coolant to allow for thermostat re-
moval. Refer to Thermostat Replacement. Disconnect
the water pump drive belt.
Disconnect the upper radiator hose from the ther-
mostat housing. Remove the housing and thermostat.
Install the thermostat housing.
Add coolant to the radiator to bring the level to
within 6.3 mm (1/4 in) of the top of the thermostat
housing.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engine and accelerate rapidly three times
(to approximately 3000 rpm) while observing the
coolant. If internal engine combustion gases are leak-
ing into the cooling system, bubbles will appear in
the coolant. If bubbles do not appear, there is no in-
ternal combustion gas leakage.
COOLANT RESERVE/OVERFLOW SYSTEM
The system works along with the radiator pressure
cap. This is done by using thermal expansion and
contraction of the coolant to keep the coolant free of
trapped air. It provides:
²A volume for coolant expansion and contraction.
²A convenient and safe method for checking/adjust-
ing coolant level at atmospheric pressure. This is
done without removing the radiator pressure cap.
²Some reserve coolant to cover minor leaks and
evaporation or boiling losses.
Fig. 20 Pressurizing SystemÐTypical
JCOOLING SYSTEM 7 - 19