1995 JEEP YJ Service And Repair Manual

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JEEP YJ 1995 Service And Repair Manual CLUTCH DIAGNOSIS
INDEX
page page
Clutch Contamination....................... 3
Clutch Cover and Disc Runout................ 3
Clutch Housing Misalignment................. 4
Clutch Misalignment........

CLUTCH DIAGNOSIS
INDEX
page page
Clutch Contamination....................... 3
Clutch Cover and Disc Runout................ 3
Clutch Housing Misalignment................. 4
Clutch Misalignment........................ 3Flywheel Runout........................... 3
General Diagnosis Information................ 3
Inspection and Diagnosis Charts............... 4
Installation Methods and Parts Usage........... 4
GENERAL DIAGNOSIS INFORMATION
Unless the cause of a clutch problem is obvious, ac-
curate problem diagnosis will usually require a road
test to confirm a problem. Component inspection will
then be required to determine the actual problem
cause.
During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
ranges and observe clutch action. If chatter, grab,
slip, or improper release is experienced, remove and
inspect the clutch components. However, if the prob-
lem is noise or hard shifting, further diagnosis may
be needed as the transmission or another driveline
component may be at fault. Careful observation dur-
ing the test will help narrow the problem area.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, water, or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter,
slip and grab.
During inspection, note if any components are con-
taminated with oil, hydraulic fluid, or water/road
splash.
Oil contamination indicates a leak at either the
rear main seal or transmission input shaft. Oil leak-
age produces a residue of oil on the housing interior
and on the clutch cover and flywheel. Heat buildup
caused by slippage between the cover, disc and fly-
wheel, can sometimes bake the oil residue onto the
components. The glaze-like residue ranges in color
from amber to black.
Road splash contamination means dirt/water is en-
tering the clutch housing due to loose bolts, housing
cracks, or through hydraulic line openings. Driving
through deep water puddles can force water/road
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals. This type of leak can only be
confirmed by visual inspection.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the in-
dicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. However, mi-
nor flywheel scoring can be cleaned up by hand with
180 grit emery, or with surface grinding equipment.
Remove only enough material to reduce scoring (ap-
proximately 0.001 - 0.003 in.). Heavy stock removal
isnot recommended.Replace the flywheel if scor-
ing is severe and deeper than 0.076 mm (0.003 in.).
Excessive stock removal can result in flywheel crack-
ing or warpage after installation; it can also weaken
the flywheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal. Tighten flywheel
bolts to specified torque only. Overtightening can dis-
tort the flywheel hub causing runout.
CLUTCH COVER AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of anewdisc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain an-
other disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
JCLUTCH DIAGNOSIS 6 - 3

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JEEP YJ 1995 Service And Repair Manual 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 t

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, mis-
alignment can also cause premature wear of the
transmission input shaft and front bearing.
Housing misalignment is generally caused by incor-
rect 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.
A cocked pilot bearing is another cause of clutch
noise, drag, and hard shifting, and rapid bearing
wear. Always use an alignment tool to install a new
bearing. This practice helps avoid cocking the bear-
ing during installation.
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

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JEEP YJ 1995 Service And Repair Manual Fig. 1 Clutch Inspection Points
JCLUTCH DIAGNOSIS 6 - 5

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JEEP YJ 1995 Service And Repair Manual 6 - 6 CLUTCH DIAGNOSISJ

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JEEP YJ 1995 Service And Repair Manual JCLUTCH DIAGNOSIS 6 - 7

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JEEP YJ 1995 Service And Repair Manual 6 - 8 CLUTCH DIAGNOSISJ

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JEEP YJ 1995 Service And Repair Manual JCLUTCH DIAGNOSIS 6 - 9

Page 232 of 2158

JEEP YJ 1995 Service And 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

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