1995 JEEP CHEROKEE Service Repair Manual

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Page 217 of 2198

JEEP CHEROKEE 1995 Service Repair Manual CLUTCH SERVICE
INDEX
page page
Clutch Component Lubrication................ 10
Clutch Cover and Disc Installation............. 10
Clutch Cover and Disc Removal.............. 10
Clutch Fluid Level.....

CLUTCH SERVICE
INDEX
page page
Clutch Component Lubrication................ 10
Clutch Cover and Disc Installation............. 10
Clutch Cover and Disc Removal.............. 10
Clutch Fluid Level......................... 14
Clutch Housing Replacement................ 13
Clutch Hydraulic Linkage Installation........... 14
Clutch Hydraulic Linkage Removal............. 13Clutch Pedal Installation.................... 15
Clutch Pedal Removal...................... 15
Clutch Safety Precautions................... 10
Flywheel Service.......................... 16
Pilot Bearing Replacement.................. 12
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 CON-
TAMINATED. DISPOSE OF ALL DUST AND DIRT
CONTAINING ASBESTOS FIBERS IN SEALED BAGS
OR CONTAINERS. THIS WILL HELP MINIMIZE EX-
POSURE 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 COMPONENT LUBRICATION
Proper clutch component lubrication is important
to satisfactory operation. Using the correct lubricant
and not overlubricating are equally important. Apply
recommended lubricant sparingly to avoid disc and
pressure plate contamination.
Clutch and transmission components requiring lu-
brication are:
²pilot bearing
²release lever pivot ball stud
²release lever contact surfaces
²release bearing bore
²clutch disc hub splines
²clutch pedal pivot shaft bore
²clutch pedal bushings²input shaft splines
²input shaft pilot hub
²transmission front bearing retainer slide surface
Never apply grease to any part of the clutch
cover, or disc.
Recommended Lubricants
Use Mopar multi-purpose grease for the clutch
pedal bushings and pivot shaft. Use Mopar high tem-
perature grease (or equivalent) for all other lubrica-
tion requirements. Apply recommended amounts and
do not overlubricate.
CLUTCH COVER AND DISC REMOVAL
(1) Remove transmission. Refer to procedures in
Group 21.
(2) If original clutch cover will be reinstalled, mark
position of cover on flywheel for assembly reference.
Use paint or a scriber for this purpose.
(3) If clutch cover is to be replaced, cover bolts can
be removed in any sequence. However, if original
cover will be reinstalled, loosen cover bolts evenly
and in rotation to relieve spring tension equally. This
is necessary 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.
6 - 10 CLUTCH SERVICEJ

Page 218 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (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)

Page 219 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (2) Disconnect release bearing from release lever
and remove bearing (Fig. 6).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face is scored,

Page 220 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (8) Install transmission. Refer to Group 21 for pro-
cedure.
CLUTCH HOUSING REPLACEMENT
The clutch housing is removable and can be re-
placed when the transmission is out of the vehicle.
The bolts att

(8) Install transmission. Refer to Group 21 for pro-
cedure.
CLUTCH HOUSING REPLACEMENT
The clutch housing is removable and can be re-
placed when the transmission is out of the vehicle.
The bolts attaching the housing to the transmission
case are located inside the housing (Fig. 8). Recom-
mended 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
shifting.
CLUTCH HYDRAULIC LINKAGE REMOVAL
The clutch master cylinder, slave cylinder
and connecting line are serviced as an assem-
bly only. The linkage components cannot be
overhauled or serviced separately. The cylin-
ders and connecting line are sealed units. Also
note that removal/installation procedures forright and left hand drive models are basically
the same. Only master cylinder location is dif-
ferent.
(1) Raise vehicle.
(2) Remove fasteners attaching slave cylinder to
clutch housing.
(3) Remove slave cylinder from clutch housing (Fig.
9).
(4) Disengage clutch fluid line from body clips.
(5) Lower vehicle.
(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. 10 and 11).
(8) Remove clip securing clutch master cylinder
push rod to pedal and slide push rod off pedal pin.
(9) Disconnect clutch pedal position switch wires.
(10) If pedal pin is equipped with bushing, inspect
condition of bushing and replace it if worn or dam-
aged.
(11) Remove clutch hydraulic linkage through en-
gine compartment.
Fig. 8 Clutch Housing AttachmentFig. 7 Pilot Bearing Installation
JCLUTCH SERVICE 6 - 13

Page 221 of 2198

JEEP CHEROKEE 1995 Service Repair Manual CLUTCH HYDRAULIC LINKAGE INSTALLATION
(1) Be sure reservoir cover on clutch master cylin-
der is tight to avoid spills.
(2) Position clutch linkage components in vehicle.
Work connecting line and slav

Page 222 of 2198

JEEP CHEROKEE 1995 Service Repair Manual If inspection or diagnosis indicates additional fluid
may be needed, use Mopar brake fluid, or an equiv-
alent meeting standards SAE J1703 and DOT 3. Do
not use any other type of fluid.
Clutch fluid l

Page 223 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (3) Install clutch master cylinder push rod on
pedal. Secure rod with washer(s) and new cotter pin.
(4) Connect clutch pedal position switch wires.
(5) Install instrument panel lower trim cover, if re

(3) Install clutch master cylinder push rod on
pedal. Secure rod with washer(s) and new cotter pin.
(4) Connect clutch pedal position switch wires.
(5) Install instrument panel lower trim cover, if re-
moved.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
Minor scratches, burrs, or glazing on the flywheel
face can be reduced with 180 grit emery cloth. How-
ever, the flywheel should be replaced if the disc con-
tact surface is severely scored, heat checked, cracked,
or obviously worn.
Flywheel machining is not recommended. The fly-
wheel surface is manufactured with a unique contour
that would be negated by machining. However,
cleanup of minor flywheel scoring can be performed
by hand with 180 grit emery, or with surface grind-
ing equipment. Replace the flywheel if scoring is
deeper than 0.0762 mm (0.003 in.).
Heavy stock removal by grinding isnot recom-
mended.Excessive stock removal can result in fly-
wheel cracking or warpage after installation. It can
also weaken the flywheel and interfere with proper
clutch release.
Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the fly-
wheel face with a dial indicator. Mount the dial indi-
cator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheelis replaced and use Mopar Lock N' Seal, or Loctite
242 on the replacement bolt threads.
Recommended flywheel bolt torques are:
²142 Nzm (105 ft. lbs.) for 6-cylinder flywheels
²68 Nzm (50 ft. lbs.) plus an additional turn of 60É
for 4-cylinder flywheels
Inspect the teeth on the starter ring gear.If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
In cases where a new flywheel is not readily avail-
able, a replacement ring gear can be installed. How-
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
(a) Mark position of the old gear for alignment
reference on the flywheel. Use a scriber for this
purpose.
(b) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han-
dling a heated ring gear.
(c) Remove the old gear by cutting most of the
way through it (at one point) with an abrasive cut-
off wheel. Then complete removal with a cold chisel
or punch.
(d) The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it.The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the
same time to produce uniform expansion. An oven
or similar enclosed heating device must be used.
Temperature required for uniform expansion is ap-
proximately 375É F.
CAUTION: Do not use an oxy/acetylene torch to re-
move the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(e) The heated gear must be installed evenly to
avoid misalignment or distortion. A shop press and
suitable press plates should be used to install the
gear if at all possible.
(f) Be sure to wear eye and hand protection.
Heat resistent gloves and safety goggles are needed
for personal safety. Also use metal tongs, vise grips,
or similar tools to position the gear as necessary
for installation.
(g) Allow the flywheel and ring gear to cool down
before installation. Set the assembly on a work-
bench and let it cool in normal shop air.
Fig. 16 Clutch Pedal Mounting (XJ)
6 - 16 CLUTCH SERVICEJ

Page 224 of 2198

JEEP CHEROKEE 1995 Service Repair Manual CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.TORQUE SPECIFICATIONS
JCLUTCH SERVI

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