1999 Jeep TJ Wrangler Service Manual - 06. Clutch

8/14/2019 1999 Jeep TJ Wrangler Service Manual - 06. Clutch

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CLUTCH

CONTENTS

page page

GENERAL INFORMATION

CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . 1

INSTALLATION METHODS AND PARTS

USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATION

CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTING

DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . 2

SERVICE PROCEDURES

CLUTCH COMPONENT LUBRICATION . . . . . . . . 9

CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 9

CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . . 9

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 10

CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 12

CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . 12

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . 13

PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . 11

RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . 11

SPECIFICATIONS

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

GENERAL INFORMATION

CLUTCH COMPONENTSThe clutch mechan ism in TJ models consists of a

s in g le , d r y-t y p e d is c a n d a d ia p h r a g m s t yl e cl u t ch

cove r. A h yd r a u lic lin k a ge is u s ed t o op er a t e t h e

clutch release bearing and fork.

A needle-type pilot bearing supports the transmis-

s ion i n pu t s h a ft i n t h e cr a n k s h a f t . A c on v en t i on a l

release bearing is used to engage and disengage the

clutch cover pressure plate.The release bearing is operated by a release fork in

t h e cl u t ch h ou s in g . T h e for k p iv ot s on a b a ll s t u d

mounted in the housing. The release fork is actuated

by a hydraulic slave cylinder mounted on the hous-

ing. The slave cylinder is operated by a clutch master

cy li n d er m ou n t e d on t h e d a s h p a n e l. T h e cy li n de r

push rod is connected to the clutch pedal.

T h e clu t ch d is c h a s cu s h ion s p ri ng s in t h e d is c

hub. The clutch disc facing is r iveted to th e h ub. The

fa ci n g i s m a d e fr om a n on -a s b es t os m a t e r i a l. T h e

clutch cover pressure plate is a diaphragm type with

a one-piece spring and multiple release fingers. The

pressure plate release fingers are preset during man-

ufacture and are not adjustable.

HYDRAULIC LINKAGE COMPONENTS

The hydraulic linkage consists of a clutch master

cylinder with integral reservoir, a clut ch slave cylin-

der and an interconnecting fluid l ine.

The clutch master cylinder pu sh rod is connected

t o t h e cl u t ch p e da l . T h e s la v e c yl in d e r p u s h r od i s

connected to the clutch release fork. The master cyl-

inder is mounted on the driver side of the dash panel

a d ja ce n t t o t h e b r a k e m a s t e r cy li n de r a n d b oos t e r

assembly. This positioning is similar for both left and

right hand drive models.

INSTALLATION METHODS AND PARTS USAGEDistortion of clutch components during installation

and the use of non-standard components are common

causes of clutch malfunction.

Improper clutch cover bolt t ightening can distort

t h e cov er . T h e u s u a l r e s u lt i s c lu t ch g r a b, ch a t t e r

and rapid wear. Tighten the cover bolts as described

in Removal and Installation section.An improperly seat ed flywheel an d/or clut ch hous-

ing are additional causes of clutch failure. Improper

s e a t in g w il l p r od u ce m i sa l ig n m en t a n d a d d it i on a l

clutch problems.

T h e u s e o f n o n - s t a n d a r d o r l o w q u a l i t y p a r t s w i l l

a l s o l ea d t o p r ob le m s a n d w ea r . U s e r e com m e n d ed

factory quality parts to avoid comebacks.

A cocked pilot bearing is another cause of clutch

n oi se , d r a g , h a r d s h ift i n g, a n d r a p i d b ea r i n g w ea r .

Always use an alignment tool to install a new bear-

i n g. T h is p r a ct i ce h e lp s a v oi d cock in g t h e b ea r i n g

during installation.

DESCRIPTION AND OPERATION

CLUTCH OPERATIONLeverage, clamping force, and friction are what make

the clutch work. The disc serves as the friction element

an d a d iap h rag m sp ri n g an d p ressu re p l at e p ro vi de t h e

clamping force. The clutch pedal, hydraulic l inkage,

release lever and bearing provide the leverage.

The clutch cover assembly clamps the disc against

the flywheel. The assembly consists of the cover, dia-

T J CLUTCH 6 - 1


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phragm spring, pressure plate, a nd fulcrum compo-

n e n t s. T h e p r es su r e p la t e cla m p s t h e clu t ch d is c

a g ai n st t h e flyw h ee l a n d t h e s pr in g p r ov id es t h e

clamping force.

The clutch disc friction material is r iveted t o the

disc hub. The hub bore is splined for installation on

t h e t r a n s m i s si on i n p u t s h a ft . T h e h u b s p li n es con -nect the disc to the transmission.

The clutch l inkage uses h ydraulic pressure to oper-

ate the clutch. The clutch master cylinder push rod is

connected to the clutch pedal and the slave cylinder

p u sh r od is con n e ct e d t o t h e r e le a se l ev er in t h e

clutch housing.

Depressing the clutch pedal develops fluid pressure

in the clutch master cylinder. This pressure is trans-

m i t t ed t o t h e s la v e cy li n de r t h r o u gh a con n e ct i n g

l in e . I n t u r n , t h e s la v e cy li n de r op e r a t es t h e cl u t ch

release lever.

T h e cl u t ch rel ease b eari n g i s m o u n t ed o n t h e t ran s-

mission front bearing retainer. The bearing is at tachedto the release lever, which moves the bearing into con-

tact with the clutch cover diaphragm spring.

Slave cylinder force causes the release lever to move

t h e release b eari n g i n t o con t act w it h t h e d iap h rag m

s p r in g. As a d dit ion a l for ce is a p plie d, t h e b ea r in g

presses the diaphragm spring fingers inward on the ful-

cru m s. T h i s act i o n m o v es t h e p ressu re p l at e rearw ard

relieving clamp force on the disc. The clutch disc is dis-

engaged and freewheeling at this point.

The process of clutch re-engagement is simply the

reverse of what occurs during disengagement. Releas-

ing pedal pressure removes clutch l inkage pressure.

The release bearing moves away from the diaphragm

s pr in g w hich a llow s t h e p r es su r e p la t e t o e xer tclamping force on the clutch disc.

DIAGNOSIS AND TESTING

DIAGNOSTIC INFORMATIONUnless th e cause of a clutch problem is obvious,

a ccu r a t e p r ob le m d ia g n os is w il l u s u a l ly r e qu i r e a

road test to confirm a problem. Component inspection

(Fig. 2) will then be required to determine the actual

problem cause.

D u r in g a r oa d t e st , d r ive t h e v eh i cle a t n or m a l

s p ee ds . S h ift t h e t r a n s m is sion t h r ou gh a ll g ea rr a n g e s a n d ob s er v e cl u t ch a ct i on . I f c h a t t e r, g r a b,

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

b e n e ed e d a s t h e t r a n s m i ss ion or a n o t h er d r iv el in e

component may be at fault . Careful observation dur-

ing the test will help narrow the problem area.

6 - 2 CLUTCH T J

DESCRIPTION AND OPERATION (Continued)


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Fig. 2 Clutch Components And Inspection

T J CLUTCH 6 - 3

DIAGNOSIS AND T ESTING (Continued)


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CLUTCH CONTAMINATION

Fluid contam ination is a frequent cause of clutch

malfunctions. Oil, water, or clutch fluid on the clutch

d is c a n d p r e ss u r e p la t e s u r fa ce s w il l c a u s e ch a t t e r ,

slip and grab.

During inspection, note if any components are con-

t a m in a t e d w it h oil, h yd r a u lic flu id , or w a te r /r oa dsplash.

O il con t a m i n a t i on i n di ca t e s a l ea k a t e it h e r t h e

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. H eat buildup

caused by slippage between the cover, disc an d fly-

w h e el , c a n s om e t im e s b a k e t h e oi l r e s id u e on t o t h e

components. The glaze-like residue ranges in color

from amber to black.

R oa d s p la s h con t a m i n a t i on m e a n s d ir t /w a t e r i s

entering the clutch housing due to loose bolts, hous-

ing cracks, or through hydraulic l ine openings. Driv-

ing through deep water puddles can force water/roadsplash 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 MI SALIGNMENT

C lu t ch com p on e n t s m u s t b e i n p r op e r a l ig n m en t

w it h t h e cr a n k s h a ft a n d t r a n s m is sion in p u t s h a ft .

Misalignment caused by excessive runout or warpage

of any clutch component will cause grab, chatter and

improper clutch release.

FLYWHEEL RUNOUTCheck flywheel runout whenever misalignment is sus-

p ect ed . F l yw h eel ru n o u t sh ou l d n ot exceed 0 .0 8 m m

(0.003 in.). Measure run out at the outer edge of the fly-

wheel face with a dial indicator. Mount the indicator on

a stud installed in place of one of the flywheel bolts.

Common causes of runout are:

h e a t w a r p a g e

improper machining

incorrect bolt tightening

improper seating on crankshaft f lange shoulder

foreign material on crankshaft flange

F l yw h eel m ach i n in g i s n ot recom m en d ed . T h e fl y-

wheel clutch surface is ma chined to a unique contour

and machining will negate this feature. However, minor

fl yw h eel scori n g can b e cl ean ed u p b y h a n d w it h 1 80

grit emery, or with surface grinding equipment. Remove

only enough material to reduce scoring (approximately

0.001 - 0.003 in.). Heavy stock removal is n o t r e c o m -

m e n d e d . Replace the flywheel if scoring is severe

a n d d e ep e r t h a n 0 .0 76 m m (0 .0 03 i n .). E x ce s si ve

s t ock r e m ov a l ca n r e s u lt i n fl yw h e el cr a ck i n g or

warpage after installation; it can also weaken the fly-

wheel and interfere with proper clutch release.

C le a n t h e cr a n k s h a ft fl a n ge b efor e m ou n t i n g t h e

flywheel. Dirt and grease on the flange surface may

cock the flywheel causing excessive runout. Use new

b ol t s w h e n r e m ou n t i n g a fl yw h e el a n d s e cu r e t h e

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

C h e ck t h e cl u t ch d is c b efor e i n s t a ll a t ion . Ax ia l

(face) r unout of a n e w disc should not exceed 0.50

mm (0.020 in.). Measure runout about 6 mm (1/4 in.)

fr om t h e ou t er e dge of t h e d is c fa cin g. O bt a in

another disc if runout is excessive.

Check condition of the clutch before installation. A

w a r p ed cov er or d ia p h r a g m s p r in g w il l c a u s e g r a b

a n d i n com p le t e r e le a s e or e n ga g em e n t . B e ca r e fu l

when han dling t he cover an d disc. Impact can distort

the cover, diaphragm spring, release fingers and the

hub of the clutch disc.Use an alignment tool when posit ioning th e disc on

the flywheel. The tool prevents accidental misalignment

which could result in cover distortion and disc damage.

A frequent cause of clutch cover distortion (and con-

sequent misalignment) is improper bolt tightening.

CLUTCH HOUSING MISALIGNMENT

C lu t ch h ou s i n g a l i gn m e n t i s i m por t a n t t o p r op e r

clutch operation. The housing maintains alignment

b et we en t h e cr a n ks h aft a n d t r a n sm is sion in p ut

s h a ft . M is a li gn m e n t ca n ca u s e cl u t ch n oi se , h a r d

shifting, incomplete release an d chatt er. I t can also

result in premature wear of the pilot bearing, coverrelease fingers and clutch disc. In severe cases, mis-

a l ign m e n t ca n a ls o c a u se p r em a t u r e w ea r of t h e

transmission input shaft and front bearing.

Housing misalignment is generally caused by incor-

rect seating on the engine or transmission, loose hous-

ing bolts, m issing a lignment dowels, or housing dam age.

Infrequently, misalignment may also be caused by hous-

ing mounting surfaces that are not completely parallel .

Misalignment can be corrected with shims.

INSPECTION AND DIAGNOSIS CHARTS

The clutch inspection chart (Fig. 2) outl ines i tems to

be checked before and during clutch installation. Use

t h e ch a r t a s a ch e ck lis t t o h e lp a void ove r look in g

potential problem sources during service operations.

The diagnosis charts describe common clutch prob-

l em s , ca u s e s a n d cor r e ct i on . F a u l t con d i t ion s a r e

listed at the top of each chart. Conditions, causes and

corrective action are outlined in the indicated col-

u m n s .

The charts are provided as a convenient reference

when diagnosing faulty clutch operation.

6 - 4 CLUTCH T J



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DIAGNOSTIC CHART

T J CLUTCH 6 - 5



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DIAGNOSTIC CHART

6 - 6 CLUTCH T J



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D I A GN O STI C C H A R T C ON TI N U ED

T J CLUTCH 6 - 7



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D I A GN O STI C C H A R T C ON TI N U ED

6 - 8 CLUTCH T J



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SERVICE PROCEDURES

CLUTCH COMPONENT LUBRICATIONProper clutch component lubrication is importan t

to satisfactory operation. Using the correct lubricant

and not over lubricating are equally important. Apply

recommended lubricant sparingly to a void disc an dpressure plate contamination.

C lu t ch a n d t r a n s m i s si on com p on e n t s r e qu i r in g

lubrication are:

Pilot bearing.

Release lever pivot ball stud.

Release lever contact sur faces.

Release bearing bore.

Clutch disc h ub splines.

Clutch pedal pivot shaft bore.

Clutch pedal bushings.

Input shaft splines.

Input shaft pilot hub.

Tr a n s m i ss ion fr on t b ea r i n g r e t a in e r s li de s u r -face.

NOTE: Never apply grease to any part of the clutch

cover, or disc.

RECOMMENDED LUBRICANTS

U s e M op a r multi-purpose grease for the clutch

p e da l b u s h in g s a n d p iv ot s h a ft . U s e M op a r high

temperature grease (or equivalent) for all other lubri-

cation requirements. Apply recommended amounts

and do not over lubricate.

CLUTCH LINKAGE FLUIDIf inspection or diagnosis indicates additional fluid

may be needed, use Mopar brake fluid, or an equiv-

a l e n t m e e t i n g s t a n d a r d s S A E J 1 7 0 3 a n d D O T 3 . D o

not use any other type of fluid.

CLUTCH FLUID LEVELThe clutch fluid reservoir, master cylinder, slave

cylinder and fluid l ines are pre-filled with fluid at

the factory during assembly operations.

The h ydraulic system should not require additional

fl u id u n d e r n or m a l ci r cu m s t a n c es . T h e r e s e r v o ir

fl ui d l ev e l w i ll a c tu a ll y i n cr ea s e a s n o rm a l

c l ut c h w e a r o c c ur s . A v o i d o v e r f i l l i ng , o r r e m o v -

i n g f lu i d f ro m t h e r e s e r v o ir.

Clutch fluid level is checked at the master cylinder

reservoir (Fig. 3). An indicator ring is provided on the

ou t sid e of t h e reserv oi r. Wi t h t h e cap an d d iap h rag m

removed, fluid level should not be above indicator ring.

To avoid contaminating the hydraulic fluid during

i n sp e ct i on , w ip e r e s er v oi r a n d cov er cl ea n b efor e

removing the cap.

FLYWHEEL

I n s p ect t h e fl yw h e el w h e n ev er t h e cl u t ch d is c,cov er a n d h ou s in g a r e r e m ov ed for s e r vi ce . C h e ck

condition of th e flywheel face, h ub, ring gear teeth,

and flywheel bolts.

Minor scratches, burr s, 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 m achining is not recommended. The fly-

wheel surface is manu factured with a unique contour

t h a t w ou ld b e n e ga t e d b y m a ch in in g . H ow eve r,

cleanu p of minor flywheel scoring can be per formed

by hand with 180 grit emery, or with surface grind-i n g e qu i pm e n t . R ep la ce t h e fl yw h e el i f s c or i n g i s

deeper than 0.0762 mm (0.003 in.).

H e a vy s t ock r e m ov a l b y g r in d in g i s n o t r e c o m -

m e n d e d . Excessive stock removal can result in fly-

wheel cracking or warpage a fter installation. I t can

also weaken the flywheel and interfere with proper

clutch release.

C h eck flyw h ee l r u n ou t if m is a lig n me n t is s u s-

p e ct e d . R u n ou t s h ou l d n ot e xce ed 0 .0 8 m m (0 .0 03

i n .). M ea s u r e r u n ou t a t t h e ou t e r e dg e o f t h e fly-

wheel face with a dial indicator. Mount the dial indi-

cator on a stud installed in place of one of the clutch

housing atta ching bolts.C le a n t h e cr a n k s h a ft fl a n ge b efor e m ou n t i n g t h e

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 flywheel

is replaced and use Mopar Lock N Seal, or Loctite

242 on the replacement bolt threads.

Recommended flywheel bolt torques are:

142 Nm (105 ft. lbs.) for 6-cylinder flywheels

Fig. 3 Clutch Master Cylinder Reservoir And Cap

T J CLUTCH 6 - 9


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6 8 N m (5 0 f t . l b s.) p lu s a n a d d it i on a l t u r n of

60 for 4-cylinder flywheels

I n s p e c t t h e t e e t h o n t h e s t a r t e r r i n g g e a r . I f t h e

t e e t h a r e w o r n o r d a m a g e d , t h e f l y w h e e l s h o u l d

b e r e p l a c e d a s a n a s s e m b l y . T h i s i s t h e r e c o m -

m e n d e d a n d p r e f e r r e d m e t h o d o f r e p a i r .

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.

(1) Mark position of the old gear for alignment ref-

e r en ce on t h e fl yw h e el . U s e a s cr i be r for t h i s p u r -

pose.

(2 ) We a r p r ot e ct i ve g og gl es or a p p r ov ed s a fe t y

g la s s es . A ls o w e a r h e a t r e s is t e n t g lov es w h e n h a n -

dling a heated ring gear.

(3) Remove the old gear by cutting most of the way

t h r o u gh i t (a t on e p oi n t ) w it h a n a b r a s iv e c u t -off

wheel. Then complete r emoval with a cold chisel or

punch.(4 ) T h e r i n g g ea r i s a s h r i n k f it on t h e fl yw h e el .

This means the gear must be expanded by heating in

or d er t o in s t a ll i t. Th e m e th o d o f h e a t in g a n d

e x p an d in g t h e g e a r i s e x tr e me ly i m po rt an t .

Every surface of the gear must be heated at the same

time to produce uniform expansion. An oven or simi-

lar enclosed h eating device must be u sed. Tempera-

ture required for uniform expansion is approximately

375 F.

CAUTION: Do not use an oxy/acetylene torch toremove the old gear, or to heat and expand a new

gear. The high temperature of the torch flame cancause localized heating that will damage the fly-wheel. In addition, using the torch to heat a replace-ment gear will cause uneven heating andexpansion. The torch flame can also anneal the

gear teeth resulting in rapid wear and damage afterinstallation.

(5 ) T h e h e a t ed g ea r m u s t b e i ns t a lle d e ve n ly t o

avoid m isalignment or distortion. A shop press and

s u it a b le p r es s p la t e s s h ou l d b e u s ed t o in s t a ll t h e

gear if at all possible.

(6) Be sure to wear eye and hand protection. Heat

r e s is t e n t g lov es a n d s a fe t y g og gl es a r e n e e de d forpersonal safety. Also use metal tongs, vise grips, or

s im i la r t ool s t o p os it i on t h e g ea r a s n e ce s sa r y for

installation.

(7) Allow the flywheel and ring gear to cool down

before installation. Set the assembly on a workbench

and let i t cool in normal shop air.

CAUTION: Do not use water, or compressed air tocool the flywheel. The rapid cooling produced bywater or compressed air can distort, or crack the

gear and flywheel.

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC

REMOVAL

(1) Remove tran smission. Refer to procedures in

Group 21.(2) If origina l clut ch cover will be reinsta lled, ma rk

position of cover on flywheel for assembly reference.

Use paint or a scriber for this purpose.

(3) If clutch cover is to be r eplaced, cover bolts can

b e r e m ov ed i n a n y s eq u e n ce . H ow ev er , i f o r ig in a l

cover will be reinstalled, loosen cover bolts evenly

and in rotation to relieve spring tension equally. This

is necessary to avoid warping cover.

(4) Remove cover bolts an d r emove cover a nd disc

(Fig. 4).

INSTALLATION

(1) Lightly scuff sa nd flywheel face with 180 grite m er y clot h . T h en cl ea n s u r fa ce w it h a w a x a n d

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 ) S lid e d is c on t o t r a n s m is sion in p u t s h a ft

splines. Disc should slide freely on splines.

(b ) L ea v e d is c o n s h a ft a n d ch e ck fa ce r u n o u t

w i t h d i a l i n d i c a t o r . C h e c k r u n o u t a t d i s c h u b a n d

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 ru nout exceeds

this l imit.

(4) Position clut ch disc on flywheel. Be su re side of

disc mar ked flywheel side is positioned against fly-

wheel (Fig. 4). If disc is not marked, be sure flat side

of disc hub is toward flywheel.

(5) Inspect condition of pr essure plate surface of

clut ch cover (Fig. 4). Replace cover if this surface is

worn, heat checked, cracked, or scored.

(6) Insert clutch alignm ent tool in clutch disc (Fig.

5).

(7) Insert alignment tool in pilot bearing and posi-

tion disc on flywheel. Be sure disc hub is positionedcorrectly. Side of hub marked Flywheel Side should

face flywheel (Fig. 4). If disc is n ot mar ked, place flat

side of disc against flywheel.

(8) Position clutch cover over disc a nd on flywheel

(Fig. 5).

(9) Insta ll clutch cover bolts finger t ight.

(10) Tighten cover bolts evenly an d in rotation a

f e w t h r e a d s a t a t i m e . C o v e r b o l t s m u s t b e t i g h t -

e n e d e v e n ly a n d t o s p e ci fi e d t o r qu e t o a v oi d

di s t o r t i ng c o v e r . T i g ht e ni ng t o r que s a r e 3 1 N m

6 - 10 CLUTCH T J

SERVI CE PROCEDURES (Continued)


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( 23 f t . l b s .) o n 2 .5 L e n g i n e s a n d 5 2 N m ( 3 8 f t .

l b s .) o n 4 .0 L e n g i n e s .

( a ) S t a r t a l l 6 b o l t s b y h a n d .

(b ) Ti gh t e n 3 p il ot h ol e b ol t s 3 /4 s of t h e w a y

(an y sequence).

(c) Start ing 180 degrees from the last pilot bolt ,

t ig h te n 3 la r ge h ol e b ol ts 3 /4 s of t h e w a y (a n y

sequence).

(d ) T ig h t en 3 p il ot h ol e b ol t s a l l t h e w a y (a n y

sequence).

(e ) S t a r t i n g 1 80 d e gr e es fr om l a st p il ot b ol t ,t ighten 3 large bolts all the way (any sequence).

(11) Apply light coat of Mopar h i g h t e m p e r a t u r e

b ea r in g g re a se t o clu t ch d is c h u b a n d s p lin e s of

t r a n s m i s si on i n pu t s h a ft . D o n o t o v e r l ub ri ca te

s h a f t s p l i n e s . T h i s w i l l r e s u l t i n g r e a s e c o n t a m -

i n a t i o n o f d i s c .

(12) Install tran smission.

RELEASE BEARING

REMOVAL

(1) Remove tr an smission.

(2) Disconnect release bearing from release lever

and remove bearing (Fig. 6).

(3) Inspect bearing slide surface of tran smissionfront bearing retainer. Replace retainer if slide sur-

face is scored, worn, or cracked.

(4 ) I n s pe ct r e le a s e for k a n d for k p iv ot . B e s u r e

pivot is secure and in good condition. Be sure fork is

not distorted or worn. Replace release fork retainer

spring if bent or damaged.

INSTALLATION

(1) Lubricate cra nksh aft pilot bear ing with Mopar

h i gh t e m p er a t u r e b ea r i n g g r ea s e . Ap p ly g r ea s e t o

end of long shank, small diameter flat blade screw-

d r i ve r. T h e n i n se r t t ool t h r o u gh cl u t ch d is c h u b t o

reach bearing.(2) Lubricate input shaft splines, bearing retainer

slide surface, fork pivot an d release fork pivot su rface

with Mopar high temperature grease.

(3) Install new release bearing. Be sure bearing is

properly secured to release fork.

(4) Install tr ansmission.

PILOT BEARING

REMOVAL

(1) Remove tr an smission.

(2) Remove clutch cover a nd disc.

(3) Remove pilot bearing. Use intern al (blind hole)

puller such those as supplied in SnapOn Tool Set

CG40CB to remove bearing.

INSTALLATION

(1) Lubricate new bearing with Mopar high tem-

perature bearing grease.

Fig. 4 Clutch Disc And Pressure Plate Inspection

Fig. 5 Typical Method Of Aligning Clutch Disc

Fig. 6 Release Bearing Attachment

T J CLUTCH 6 - 11

REMOVAL AND INSTALLATION (Continued)


12/14

(2 ) St a r t n e w b ea r in g in t o cr a n k s h a ft b y h a n d .

Then seat bearing with clutch alignment tool (Fig. 7).

(3) Lightly scuff sand flywheel su rface with 180

g r it e m er y cl ot h . T h en cl ea n s u r fa ce w it h w a x a n d

grease remover.

(4 ) I n s t a l l cl u t ch d is c a n d cov er a s d e scr i be d i n

this section.

(5) Install transmission.

CLUTCH HOUSINGT he clu t ch h ou s in g is r em ova ble a n d ca n be

replaced when the transmission is out of the vehicle.

T h e b o l t s a t t a c h i n g t h e h o u s i n g t o t h e t r a n s m i s -

sion case are located inside the housing (Fig. 8). Rec-

ommended tightening torque for the clutch housing-to-transmission bolts is 38 Nm (28 ft. lbs.).

NOTE: Be sure the transmission and housing mat-ing surfaces are clean before installing an original,

or replacement clutch housing. Dirt/foreign materialtrapped between the housing and transmission willcause misalignment. If misalignment is severeenough, the result will be clutch drag, incomplete

release and hard shifting.

CLUTCH HYDRAULIC LINKAGE

The clutch master cylinder, slave cylinder and con-n e ct i n g l i n e a r e s er v ice d a s a n a s s em b ly on l y. T h e

linkage components cannot be overhauled or serviced

s e pa r a t e l y. T h e cy li n de r s a n d con n e ct i n g l in e a r e

sealed units. Also note that removal/installation pro-

cedures for right a nd left han d drive models are basi-

ca lly t h e s a m e. O n ly m a s t er cy lin d er loca t ion is

different.

REMOVAL

(1) Raise vehicle.

(2) Remove fasteners atta ching slave cylinder to

clutch housing.

(3 ) R em ov e s la v e cy li n d er fr om cl u t ch h ou s in g

(Fig. 9).(4) Disengage clutch fluid line from body clips.

(5) Lower vehicle.

(6) Verify tha t cap on clutch ma ster cylinder reser-

voir is tight. This is necessary to avoid spilling fluid

during removal.

(7) Remove clutch master cylinder a ttaching n uts

(Fig. 9) or (Fig. 10).

(8) Disengage captur ed bush ing on clutch master

cylinder actuator from pivot pin on pedal arm.

(9) Slide a ctuat or off pivot pin.

(1 0) D is con n e ct cl u t ch i n t er l ock s a fe t y s w it ch

wires.

(11 ) R em ov e cl u t ch h y d r a u li c l in k a g e t h r o u gh

engine compartm ent.

INSTALLATION

(1) Be sur e reservoir cover on clutch ma ster cylin-

der is t ight to avoid spills.

(2) Position clut ch linkage component s in vehicle.

Work connecting l ine and slave cylinder downward

past engine and adjacent to clutch housing (Fig. 9) or

(Fig. 10).

Fig. 7 Pilot Bearing Installation

Fig. 8 Clutch Housing Attachment

6 - 12 CLUTCH T J



13/14

(3) Position clutch master cylinder on dash panel

(Fig. 9) or (Fig. 10).

(4) Attach clutch master cylinder actuator to pivot

pin on clutch pedal.

(5 ) I n st a ll a n d t igh t e n clu t ch m a s t er cy lin d er

attaching nuts to 38 Nm (28 ft . lbs.) torque.

(6) Raise vehicle.

(7) Insert slave cylinder pu sh rod th rough clutch

housing opening and into release lever. Be sure cap

on end of rod is securely engaged in lever. Check this

before installing cylinder attaching nuts.

(8 ) I n s t a ll a n d t i gh t e n s la v e cy li n de r a t t a c h in g

nuts to 23 Nm (17 ft . lbs.) torque.

(9) Secure clutch fluid l ine in body an d tran smis-

sion clips.

(10) Lower vehicle.

(11) Conn ect clutch interlock safety switch wires.

CLUTCH PEDAL

REMOVAL

(1) Remove steering column lower cover and knee

b lock e r for a cce ss . R efe r t o G r ou p 8 E , I n s t r u m e n t

Panel for procedure.

(2) Disconnect clutch pedal p osition switch wires.

(3) Disengage captur ed bush ing lock tabs atta ch-

i n g cl u t ch m a s t e r cy li n de r a ct u a t o r t o p e da l p iv ot

(Fig. 11) or (Fig. 12).

(4) Remove nuts at taching pedal and bracket to dash

panel and upper cowl support (Fig. 11) or (Fig. 12).

(5) Separa te peda l assemble from vehicle.

INSTALLATION

(1 ) P l a ce cl u t ch p e da l a n d b r a ck e t ov er s t u d s on

dash panel and cowl support (Fig. 11) or (Fig. 12).

(2) I n st a ll n u t s t o a t t a ch p ed a l a n d br a ck et t o

dash panel and upper cowl support (Fig. 11) or (Fig.

12). Tighten nuts to 39 Nm (29 ft . lbs.) torque

(3) En ga ge ca p tu r ed b us h in g a n d a ct u a t or on

brake pedal pivot (Fig. 11) or (Fig. 12).

(4) Connect clutch pedal position switch wires.

Fig. 9 Slave Cylinder and Left Hand Drive ClutchMaster Cylinder

Fig. 10 Right Hand Drive Clutch Master Cylinder

Fig. 11 Clutch Pedal Mounting

T J CLUTCH 6 - 13



14/14

SPECIFICATIONS

TORQUE

D ES CRIP TION TORQU E

Bolts, clutch cover 2.5 L . . . . . . . 31 Nm (23 ft. lbs)

Bolts, clutch cover 4.0 L . . . . . . . 52 Nm (38 ft. lbs)Nut, clutch master cyl. . . . . . . . . 38 Nm (28 ft . lbs)

Nut, clutch slave cyl. . . . . . . . . . . 23 Nm (17 ft. lbs)

Bolt, clutch housing M12 . . . . . . . 75 Nm (55 ft. lbs)

Bolt, clutch housing 3/8 . . . . . . . . 37 Nm (27 ft. lbs)

Bolt, clutch housing 7/16 . . . . . . . 58 Nm (43 ft. lbs)

Bolt, clutch housing/tra ns. . . . . . 38 Nm (28 ft. lbs)

Bolt, dust shield M8 . . . . . . . . . . . 8 Nm (72 in. lbs)

Bolt, dust sh ield lower . . . . . . . . 50 Nm (37 ft . lbs)

Bolt, X-member/frame . . . . . . . . . 41 Nm (30 ft. lbs)

Bolt, X-member/rear support . . . 45 N m (33 ft. lbs.)

Bolts, flywheel 2.5 L . . 68 Nm (50 ft. lbs) +1/4 tu rn

Bolts, flywheel 4.0 L . . . . . . . . 142 Nm (105 ft. lbs)

Fig. 12 Clutch Pedal MountingRight Hand Drive

6 - 14 CLUTCH T J

SPECIFICATIONS (Continued)

Documents

1999 Jeep TJ Wrangler Service Manual - 06. Clutch