Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1997.1999-2001 Approved 1999 XJ Jeep Cherokee EXJ_6
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XJ CLUTCH 6-1
CLUTCH
CONTENTS
page page
GENERAL INFORMATION MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES
CLUTCH HYDRAULIC FLUID . . . . . . . . . . . . . . . 2 CLUTCH COMPONENT LUBRICATION . . . . . . . . 8
CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . 2 CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION METHODS AND PARTS CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . . 8
USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 9
CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . 11
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . . . 3 PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . 3 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSTIC CHARTS . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION The clutch disc has cushion springs in the disc
hub. The clutch disc facing is riveted to the hub. The
CLUTCH COMPONENTS facing is made from a non-asbestos material. The
The clutch mechanism consists of a single, dry-type clutch cover pressure plate is a diaphragm type with
disc and a diaphragm style clutch cover. A hydraulic a one-piece spring and multiple release fingers. The
linkage is used to operate the clutch release bearing pressure plate release fingers are preset during man-
and fork. ufacture and are not adjustable.
A needle-type pilot bearing in the crankshaft
flange supports the transmission input shaft. A HYDRAULIC LINKAGE COMPONENTS
sleeve type release bearing is used to engage and dis- The hydraulic linkage consists of a clutch master
engage the clutch cover pressure plate. cylinder with integral reservoir, a clutch slave cylin-
The release bearing is operated by a release fork in der and an interconnecting fluid line.
the clutch housing. The fork pivots on a ball stud The clutch master cylinder push rod is connected
mounted in the housing. The release fork is actuated to the clutch pedal. The slave cylinder push rod is
by a hydraulic slave cylinder mounted in the hous- connected to the clutch release fork. The master cyl-
ing. The slave cylinder is operated by a clutch master inder is mounted on the driver side of the dash panel
cylinder mounted on the dash panel. The cylinder adjacent to the brake master cylinder and booster
push rod is connected to the clutch pedal. assembly. This positioning is similar for both left and
right hand drive models.
6-2 CLUTCH XJ
GENERAL INFORMATION (Continued)
SAFETY PRECAUTIONS Use Mopar multi-mileage grease or a silicone
grease for the clutch pedal bushings and pivot shaft.
WARNING: EXERCISE CARE WHEN SERVICING Use Mopar high temperature bearing grease or
CLUTCH COMPONENTS. FACTORY INSTALLED equivalent for the pilot bearing, release bearing bore,
CLUTCH DISCS DO NOT CONTAIN ASBESTOS transmission input shaft and release fork compo-
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY nents. Apply recommended amounts only and do not
CONTAIN ASBESTOS FIBERS FROM AFTERMAR- overlubricate.
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE INSTALLATION METHODS AND PARTS USAGE
SERIOUS BODILY HARM. WEAR A RESPIRATOR Distortion of clutch components during installation
DURING SERVICE AND NEVER CLEAN CLUTCH and the use of non-standard components are common
COMPONENTS WITH COMPRESSED AIR OR WITH causes of clutch malfunction.
A DRY BRUSH. EITHER CLEAN THE COMPONENTS Improper clutch cover bolt tightening can distort
WITH A WATER DAMPENED RAGS OR USE A VAC- the cover. The usual result is clutch grab, chatter
UUM CLEANER SPECIFICALLY DESIGNED FOR and rapid wear.
REMOVING ASBESTOS FIBERS AND DUST. DO NOT An improperly seated flywheel and/or clutch hous-
CREATE DUST BY SANDING A CLUTCH DISC. ing are additional causes of clutch failure. Improper
REPLACE THE DISC IF THE FRICTION MATERIAL IS seating will produce misalignment and additional
DAMAGED OR CONTAMINATED. DISPOSE OF ALL clutch problems.
DUST AND DIRT CONTAINING ASBESTOS FIBERS The use of non-standard or low quality parts will
IN SEALED BAGS OR CONTAINERS. THIS WILL also lead to problems and wear. Only use recom-
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO mended factory parts.
OTHERS. FOLLOW ALL RECOMMENDED SAFETY A cocked pilot bearing is another cause of clutch
PRACTICES PRESCRIBED BY THE OCCUPATIONAL noise, drag, hard shifting, and rapid bearing wear.
SAFETY AND HEALTH ADMINISTRATION (OSHA) Always use an alignment tool to install a new bear-
AND THE ENVIRONMENTAL SAFETY AGENCY ing. This practice helps avoid cocking the bearing
(EPA), FOR THE HANDLING AND DISPOSAL OF during installation.
PRODUCTS CONTAINING ASBESTOS.
DESCRIPTION AND OPERATION
CLUTCH HYDRAULIC FLUID
If inspection or diagnosis indicates additional fluid CLUTCH OPERATION
may be needed, it will be necessary to replace the Leverage, clamping force, and friction are what
complete hydraulic linkage assembly. make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
CLUTCH LUBRICATION provide the clamping force. The clutch pedal, hydrau-
Proper clutch component lubrication is important lic linkage, release lever and bearing provide the
to satisfactory operation. Using the correct lubricant leverage.
and avoiding over lubrication are also equally impor- The clutch cover assembly clamps the disc against
tant. the flywheel. The assembly consists of the cover, dia-
During service, apply recommended lubricant spar- phragm spring, pressure plate, and fulcrum compo-
ingly. Do not overlubricate as this could result in nents. The pressure plate clamps the clutch disc
clutch disc and pressure plate contamination. against the flywheel and the spring provides the
Clutch and transmission components requiring clamping force.
lubrication are: The clutch disc friction material is riveted to the
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