J CLUTCH
CLUTCH
CONTENTS
page
GENERAL INFORMATION 1 CLUTCH SERVICE
SERVICE DIAGNOSIS 4 TORQUE SPECIFICATIONS
GENERAL INFORMATION
INDEX
page
Clutch Components 1 Clutch Fluid
Clutch Hydraulic System 1 General Service Information
CLUTCH COMPONENTS
A hydraulically operated clutch mechanism is used on
all Jeep models with manual transmission. Basic clutch
components consist of the: disc; clutch cover; hydraulic
concentric bearing; and pilot bushing (Fig. 1).
The clutch disc is a single, dry-disc unit with cushion
springs in the disc hub. The clutch disc friction material
is riveted to the hub.
The clutch cover is a diaphragm type unit with a
one-piece diaphragm spring and multiple release fin­
gers.
Clutch disc diameter is 266 m m (10.5 inch) on six-
cylinder models and 232 m m (9.28 inch) on four-cyl­
inder models.
CLUTCH HYDRAULIC SYSTEM
The clutch hydraulic system consists of t h e clutch
master cylinder; the hydraulic concentric bearing; and
the fluid lines (Fig. 2).
The clutch master cylinder is mounted on the drivers
side of the dash panel adjacent to t h e brake master
cylinder. The cylinder is operated by a suspended type
clutch pedal (Fig. 2).
The hydraulic concentric bearing is a unique design;
It incorporates the release bearing and slave cylinder in
a single assembly. The bearing is permanently attached
to the cylinder piston. The hydraulic lines are perma­
nently attached to t h e cylinder and bearing assembly
and are not removable.
The hydraulic concentric bearing completely encir­
cles t h e transmission input shaft. In operation, piston
movement causes the bearing to move in a linear
(straight line) direction.
6 -1
page
11
17
page
1
cardiagn.com
1
CLUTCH FLUID
Clutch system fluid level is checked at t h e clutch
master cylinder (Fig. 3). Fluid level is indicated by the
MAX and MIN indicators on t h e cylinder reservoir.
Check and top off fluid level to t h e MAX mark. Do not
allow level to fall below t h e MIN mark.
The only fluid recommended for use in t h e clutch
hydraulic system is Mopar Brake Fluid, or a n equiva­
lent meeting SAE J-1703 and DOT 3 standards. Do not
use any any other type of fluid.
Never u s e reclaimed brake fluid or fluid from a n
u n s e a l e d container. In addition, d o n o t u s e fluid
from a container that h a s b e e n o p e n e d a n d al­
l o w e d to stand for any length of time. Moisture i n
the air c a n b e absorbed b y the fluid causing dilu­
tion a n d loss of effectiveness.
GENERAL SERVICE INFORMATION
The hydraulic concentric bearing is serviced as a n
assembly. It cannot be disassembled for repair. The
hydraulic lines are permanently attached to the assem­
bly. They will leak if loosened or if removal is attempt­
ed.
Nylon retaining straps are installed on t h e concentric
bearing during manufacture. The straps hold the bear­
ing piston in place during shipment and installation. It
is not necessary to cut or remove t h e straps after bear­
ing installation. The straps are designed to disconnect
the first time piston movement occurs.
The clutch master cylinder can be disassembled for
repair. A service kit containing a replacement plunger
and seal assembly is available for overhaul purposes.
The clutch disc, cover, pilot bushing and hydraulic
fluid lines are all serviced as assemblies.
6 - 2 CLUTCH

4-CYLINDER CLUTCH
COMPONENTS

CLUTCH HOUSING

BRACE
ROD

COVER
BOLTS/WASHERS
HYDRAULIC
CONCENTRIC
CLUTCH BEARING
COVER

CLUTCH
DISC

cardiagn.com
PIN RETAINING
NUT
INSPECTION
COVER
PILOT
BEARING

6-CYLINDER CLUTCH
COMPONENTS

CLUTCH
HOUSING

SPACER
PLATE

COVER
BOLTS
PILOT
BEARING

J9006-1

Fig. 1 Clutch Components

 CLUTCH 6-3

WRANGLER/YJ
HYDRAULIC SYSTEM PEDAL
SHAFT

CLUTCH
PEDAL
SPRING

CYLINDER
BRACKET

cardiagn.com
HYDRAULIC PEDAL SPRING
CONCENTRIC
BEARING
FLUID
LINE

CHEROKEE/WAGONEER/COMANCHE
HYDRAULIC SYSTEM

CLUTCH
PEDAL
CYLINDER
BRACKET

CLUTCH
MASTER CYLINDER

HYDRAULIC
CONCENTRIC
BEARING
J9006-2

Fig. 2 Clutch Hydraulic System

6 -4 CLUTCH
J9006-3
Fig. 3 Clutch Fluid Level
SERW1CE D I A G N O S I S
INDEX
page
General Diagnosis Information 4 Inspection And Diagnosis Charts
Clutch Problem Causes 4
GENERAL DIAGNOSIS INFORMATION
Unless t h e cause of a clutch problem is extremely
obvious, accurate problem diagnosis will require a road
test to verify a a clutch problem followed by component
inspection to determine t h e actual problem cause.
During a road test, drive the vehicle at normal speeds.
Shift the transmission through all gear ranges and ob­
serve clutch action. If chatter, grab, slip, or improper
release is experienced, remove and inspect the clutch
components. However, if the problem is noise or hard
shifting, further diagnosis may be needed as the trans­
mission or another driveline component may be at fault.
Careful observation during the test will help narrow the
problem area.
CLUTCH PROBLEM CAUSES
Contamination
Fluid contamination is t h e most frequent cause of
clutch malfunctions. Oil, water, or clutch fluid on t h e
clutch contact surfaces will result in faulty operation.
The usual result is chatter, slip and grab.
J
cardiagn.com
page
5
During inspection, note if any components are con­
taminated with oil, hydraulic fluid, or water/road
splash.
Oil contamination indicates a leak a t either the rear
main seal or transmission input shaft. Oil leakage pro­
duces a residue of oil on the housing interior and on the
clutch cover and flywheel. Heat buildup caused by slip­
page between t h e cover, disc and flywheel, can some­
times bake t h e 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 t h e 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 from loose or damaged concen­
tric bearing lines or connections. However, clutch fluid
leaks will usually be noted and corrected before severe
contamination occurs.
J CLUTCH
Clutch Misalignment
Clutch components must be in proper alignment with
the crankshaft and transmission input shaft. Misalign­
ment caused by excessive runout or warpage of any
clutch component will cause grab, chatter and improper
clutch release.
Flywheel Runout
Check flyweel runout whenever misalignment is sus­
pected. Flywheel runout should not exceed .08 mm (.003
inch). Measure runout at the outer edge of the flywheel
face with a dial indicator. Mount the dial indicator on
a stud installed in place of one of the flywheel attaching
bolts.
Common causes of runout are heat warpage, improper
machining, mounting t h e flywheel on a dirty crank­
shaft flange, incorrect bolt tightening and improper
seating on the crankshaft flange shoulder.
Cleanup of minor flywheel scoring should be per­
formed with surface grinding equipment. Remove only
enough material to reduce scoring (approximately .001
- .003 inch). Heavy stock removal is n o t recommend­
ed. Replace the flywheel if scoring is severe and deeper
t h a n .003 inch. Excessive stock removal can result in
flywheel cracking or warpage after installation; it can
also weaken t h e flywheel and interfere with proper
clutch release.
Clean the crankshaft flange before mounting the fly­
wheel. 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 spec­
ified torque only. Overtightening can distort t h e fly­
wheel hub causing runout.
Clutch Cover And Disc Runout
Check the clutch disc before installation. Axial (face)
runout of a n e w disc should not exceed ,5 m m (.020
inch). Measure runout about 1/4 inch from the outer
edge of the disc facing. Obtain another 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 when
handling t h e cover and disc. Impact can distort t h e
cover, diaphragm spring, release fingers and the hub of
the clutch disc.
6-5
Use a n 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 con­
sequent misalignment) is improper bolt tightening. To
avoid warping the cover, the bolts must tightened al­
ternately (diagonal pattern) and evenly (2-3 threads a t
a time) to specified torque.
Clutch Housing Misalignment And Runout
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment be­
tween t h e crankshaft a n d transmission input shaft.
Misalignment can cause noise, incomplete release and
chatter; It can also result in premature wear of the pilot
bearing, cover release fingers and clutch disc. In severe
cases, misalignment can also cause premature wear of
the transmission input shaft and the shaft bearing.
Housing misalignment is generally caused by incor­
cardiagn.com
rect seating on the engine or transmission, loose hous­
ing bolts, missing alignment dowels or housing damage.
Infrequently, misalignment m a y also be caused by
housing mounting surfaces t h a t are not parallel.
Installation Methods And Parts Usage
Distortion of clutch components during installation
and the use of non-standard components are additional
causes of clutch malfunction.
Improper clutch cover bolt tightening can distort the
cover. The usual result is clutch grab, chatter and rapid
wear. Tighten t h e cover bolts as described in Clutch
Service section.
Improperly seated flywheels and clutch housings are
other causes of clutch failure. Improper seating will
produce misalignment and subsequent clutch problems.
The use of non-standard or low quality parts can also
lead to problems and wear. Use the recommended fac­
tory quality parts to avoid comebacks.
INSPECTION AND DIAGNOSIS CHARTS
The clutch inspection chart (Fig. 4) outlines items to
be checked before and during clutch installation. Use
the chart as a check list to help avoid overlooking po­
tential problem sources during service operations.
The diagnosis charts describe common clutch prob­
lems, causes and correction. Fault conditions are listed
at the top of each chart. Conditions, causes and correc­
tive action are outlined in the indicated columns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
6 -6 CLUTCH
1 Make sure side of clutch disc marked "flywheel side"
is toward flywheel.
2 Check flywheel bolt torque. If bolts are loose,
replace them. Use Mopar Lock and Seal to secure
new bolts.
3 Check pilot bearing. Replace bearing if brinnelled,
seized, or noisy. Lube bearing with wheel bearing
grease before installation.
4 Check transmission input shaft. Clutch disc must slide
freely on shaft splines. Lightly grease splines before
installation. Replace shaft if splines or pilot bearing
hub are damaged.
5 Check crankshaft flange (if flywheel is removed). Be
sure flange is clean and flywheel bolt threads are
in good condition.
6 Check rear main seal if clutch disc and cover were
oil covered. Replace seal if necessary.
7 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed .5 mm
(.02 in.).
Fig. 4 Clutch Inspection
J
8 Check flywheel condition and runout. Scuff sand
flywheel face to remove glaze. Clean surface with
a wax and grease remover afterward. Replace
flywheel if severely scored, worn or cracked. Secure
flywheel with new bolts (if removed). Do not reuse
old bolts. Use Lock and Seal on bolts.
9 Check clutch housing bolts. Tighten if loose. Be sure
housing is fully seated on engine block. Also be sure
locating dowels are in place.
10 Check flywheel face runout if chatter or grab was
encountered. Runout should not exceed .08 mm
(.003 in.).
11 Tighten dutch cover bolts 2-3 threads at a time, alter­
nately and evenly (in a diagonal pattern) to specified
torque. Failure to do so could warp the cover.
cardiagn.com
12 Check clutch cover. Replace if warped, cracked, bent.
Be sure cover is correct size and properly aligned
on disc and flywheel.
13 Check clutch cover diaphragm spring and release
fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with fac­
tory clutch spring setting. Clutch problems will result.
14 Inspect concentric bearing hydraulic lines. Be sure
connections are tight and not cross threaded.
Replace bearing assembly only if lines are loose, or
leaking.
15 Transmission input shaft bearing will cause noise,
chatter, or improper release if damaged. Check con­
dition before installing transmission.
16 Check input shaft seal if clutch cover and disc were
oil covered. Replace seal if worn, or cut.
17 Check concentric bearing mounting pin and retain­
ing nut. Never reuse old retaining nut. Use new part
only. Be sure pin is secure and in good condition.
18 Do not replace hydraulic concentric bearing unless
actually faulty. Replace bearing only if it leaks, is
seized, or damaged.
19 Inspect clutch housing. Be sure locating dowels are
in position and bolts are tight. Replace housipg if
cracked, or damaged. If clutch problems ocurred,
check runout, to be sure housing is square with
flywheel and transmission input shaft.
20 Check condition of pressure plate surface. Replace
clutch cover if plate surface is deeply scored,
warped, worn, or cracked.
Points J9006-11
J CLUTCH 6- 7

CLUTCH SLIPS
Condition Found Cause Correction
1. Disc facing worn out a) Normal wear Replace clutch disc. Also replace
cover if spring is weak or pressure
b) Driver frequently "rides" plate surface is damaged.
(slips) clutch. Results in rapid
wear overheating.

c) Insufficient clutch cover

2. Clutch disc facing
contaminated with oil, grease,
or clutch fluid.
diaphragm spring tension.
a) Leak at rear main seal or at
transmission input shaft seal.
b) Excessive amount of grease
applied to input shaft splines.
Replace leaking seals. Apply less
grease to input shaft splines.
Replace concentric bearing only if
actually leaking. Replace clutch disc
(do not clean and reuse). Clean

cardiagn.com
clutch cover and reuse only if cover
c) Leak from concentric bearing is in good condition.
or bearing hydraulic line
fittings.
3. Clutch is running partially Concentric bearing sticking-binding. Verify that bearing is actually
disengaged. Does not return to normal running binding, then replace bearing.
position.
4. Flywheel height incorrect. Flywheel surface improperly Replace flywheel.
machined. Too much stock removed
or surface is tapered.
5. Wrong disc or pressure plate Incorrect parts order or model Replace with correct parts.
installed. number. Compare old and new parts before
installation.
6. Clutch disc, cover and/or a) Rough handling (impact) bent Install new disc or cover as needed.
diaphragm spring, warped, cover, spring, or disc. Follow installation/tightening
distorted. instructions.
b) Incorrect bolt tightening
sequence and method caused
warped cover.
7. Facing on flywheel side of disc Flywheel surface scored and nicked. Reduce scores and nicks by sanding
torn, gouged, worn. or surface grinding. Replace
flywheel if scores-nicks are deeper
than .002-.004 inch.
8. Clutch disc facing burnt a) Frequent operation under high Scuff sand flywheel. Replace clutch
(charred). Flywheel and cover loads or hard acceleration cover and disc. Alert driver to
pressure plate surfaces heavily conditions. problem cause.
glazed.
b) Driver frequently "rides"
(slips) clutch. Results in rapid
wear and overheating of disc
and cover.

J9006-13
6 -8 CLUTCH J

IMPROPER CLUTCH RELEASE

Condition Found Cause Correction
1. Clutch disc warped. New disc not checked for axial Replace disc. Be sure runout of new
runout before installation. disc is less than .5 mm (.020 in.).
2. Clutch disc binds on input a) Clutch disc hub splines Clean, smooth and lubricate disc
shaft splines. damaged during installation. and shaft spines. Replace disc
and/or input shaft if splines are
b) Input shaft splines rough, severely damaged.
damaged.

c) Corrosion, rust formations on

splines of disc and input shaft.
3. Clutch disc rusted to flywheel Occurs in vehicles stored, or not Remove clutch cover and disc. Sand
and/or pressure plate. driven for extended periods rusted surfaces clean with 180 grit

cardiagn.com
of time. paper.
4. Clutch disc facing sticks to Vacuum may form in pockets over Drill 1/16 inch diameter hole
flywheel. rivet heads in clutch disc. Occurs as through rivets and scuff sand disc
clutch cools down after use. facing with 180 grit paper.
5. Clutch disc too thick. Wrong disc installed. Replace disc.
6. Pilot bearing seized. a) Bearing cocked during Lubricate and install new bearing.
installation. Check and correct any
misalignment.
b) Bearing defective.

c) Bearing not lubricated.

d) Clutch misalignment.
7. Clutch will not disengage a) Low fluid level in cutch master a) Top off cylinder and check for
properly. cylinder. leaks.

b) Air in clutch hydraulic system. b) Bleed and refill system.

c) Clutch cover loose. c) Tighten bolts.

d) Wrong clutch disc. d) Install correct disc.

e) Disc bent, distorted during e) Replace disc.

installation.

f) Clutch cover diaphragm spring f) Replace cover.

bent or warped during
transmission installation.

g) Clutch disc installed g) Remove and reinstall disc

backwards. correctly. Be sure disc side
marked "to flywheel" is
actually toward flywheel.

J9006-14
J
CLUTCH GRAB/CHATTER
Condition Found
1. Clutch disc facing covered with
oil, grease, or clutch fluid.
2. Clutch disc and/or cover
warped, or disc facings exhibit
unusual wear or appear to be
wrong type.
3. Clutch master cylinder plunger
or concentric bearing
dragging-binding.
4. No fault found with clutch
components.
5. Partial engagement of clutch
disc (one side worn-opposite
side glazed and lightly worn).
Cause
a) Oil leak at rear main or input
shaft seal.
b) Too much grease applied to
splines or disc and input shaft.
c) Concentric bearing, line or
fittings leaking fluid.
Incorrect or substandard parts.
a) Cylinder components worn or
corroded.
b) Concentric bearing is faulty.
a) Problem actually related to
suspension or driveline
component.
b) Engine related problem.
a) Clutch pressure plate position
setting incorrect or modified.
b) Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
c) Clutch disc damaged or
distorted.
d) Clutch misalignment.
CLUTCH 6-9
Correction
a) Correct leak and replace disc
(do not clean and reuse the
disc).
b) Apply lighter grease coating
to splines and replace disc (do
not clean and reuse the disc).
c) Replace concentric bearing
and replace disc (do not clean
and reuse the disc).
Replace disc and/or cover with
correct parts.
cardiagn.com
a) Overhaul or replace clutch
master cylinder.
b) Replace the bearing.
a) Further diagnosis required.
Check engine/transmission
mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Check EFI and igniton systems.
a) Replace clutch cover and disc.
b) Replace clutch cover and disc.
c) Replace disc.
d) Check alignment and runout of
flywheel, disc, or cover.
Correct as necessary.
J9006-15
6-10 CLUTCH J

CLUTCH NOISE
Condition Found Cause Correction
1. Clutch components damaged Incorrect or sub-standard clutch Replace with parts of correct type
or worn out prematurely. parts. and quality.
2. Pilot bearing seized or a) Bearing cocked or scored a), b), c) Replace bearing. Be
bearing rollers are brinneled. during installation. sure it is properly seated and
b) Bearing not lubricated prior to lubricated before installing
installation. clutch.
c) Bearing defect.

d) Clutch misalignment. d) Check and correct

misalignment caused by
excessive runout of flywheel,
disc, or cover. Replace input

3. Loose components.
4. Components appear
overheated. Hub of disc
cracked or torsion damper
springs are distorted or
broken.
5. Contact surface of concentric
bearing damaged.
Attaching bolts loose at flywheel,
cover, or clutch housing.
Frequent high load, full throttle
operation.
a) Clutch cover incorrect, or
release fingers are bent or
distorted causing damage.
cardiagn.com
shaft if bearing hub is
damaged.
Tighten bolts to specified torque.
Replace any clutch bolts that are
damaged.
Replace parts as needed. Alert
driver to condition causes.
a) Replace clutch cover and
concentric bearing.

b) Concentric bearing defect. b) Replace concentric bearing.

c) Concentric bearing misaligned. c) Check and correct runout of

clutch components. Also check
input shaft and bearing
condition. Replace shaft and
bearing if worn or damaged.
6. Concentric bearing is noisy. Concentric bearing defect. Replace concentric bearing.
7. Clutch pedal squeak. a) Pivot pin loose. Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
b) Pedal bushings worn out or and bushings with silicone base
cracked. lubricator chassis grease.

J9006-16
J CLUTCH 6-11

CLUTCH SERVICE

INDEX

page page
Clutch Safety Precautions 11 Clutch Master Cylinder Installation 13
Clutch Cover and Disc Removal 11 Clutch Master Cylinder Overhaul 13
Clutch Cover and Disc Installation 11 Hydraulic Concentric Bearing Replacement 13
Pilot Bearing Replacement 12 Clutch System Bleeding 15
Clutch Master Cylinder Removal 12

CLUTCH SAFETY PRECAUTIONS
WARNING: EXTREME CARE MUST BE EXERCIZED
WHEN SERVICING CLUTCH COMPONENTS. DUST
AND DIRT THAT ACCUMULATES ON CLUTCH PARTS
DURING NORMAL USE MAY CONTAIN ASBESTOS FI­
BERS. BREATHING EXCESSIVE CONCENTRATIONS
OF THESE FIBERS CAN CAUSE SERIOUS BODILY
HARM. WEAR A RESPIRATOR WHEN CLEANING
indicator. Check at the disc hub and about 1/4 inch from
the outer edge of the facing. Runout should not exceed
.5 mm (.020 inch). Obtain another clutch disc if runout
exceeds specified limit.
(2) Insert a clutch alignment tool in the clutch disc.
(3) Insert the alignment tool in the pilot bearing and
position the disc on the flywheel. Be sure the disc hub
is positioned correctly. Side of hub marked Flywheel

cardiagn.com
CLUTCH COMPONENTS AND NEVER CLEAN Side should face toward flywheel (Fig. 9).
CLUTCH COMPONENTS WITH COMPRESSED AIR OR (4) Position the clutch cover over the disc and on the
WITH A DRY BRUSH. USE A VACUUM CLEANER SPE­ flywheel.
CIFICALLY DESIGNED FOR REMOVING ASBESTOS (5) Install all of the clutch cover bolts finger tight.
FIBERS AND DUST. IF A VACUUM CLEANER IS NOT (6) Tighten the cover bolts evenly (and in rotation) a
AVAILABLE, CLEAN THE PARTS WITH WATER few threads a t atime. The cover bolts must be tight­
DAMPENED SHOP RAGS. DO NOT CREATE DUST BY
e n e d evenly and t o specified torque to avoid dis­
SANDING A CLUTCH DISC. IF THE DISC FRICTION
t o r t i n g the cover. Correct tightening torques are:
SURFACE IS DAMAGED OR CONTAMINATED, RE­
31 N*m (23ft-lbs) o n four-cylinder models a n d 54
PLACE THE DISC. DISPOSE OF ALL DUST AND DIRT
N»m (40 ft-lbs) o n six-cylinder models.
SUSPECTED OF CONTAINING ASBESTOS FIBERS (7) Apply a light coating of chassis grease to t h e
OR DUST IN SEALED BAGS OR CONTAINERS. THIS
splines of the transmission input shaft. Do not over-
WILL HELP MIMINIZE EXPOSURE TO YOURSELF AND
lubricate t h e shaft splines. This c a n result i n
TO OTHERS. FOLLOW ALL RECOMMENDED SAFETY
grease contamination of the disc.
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 the clutch housing/transmission/transfer
case as an assembly. See Group 21 Manual Transmis­
sion for procedure.
(2) Loosen the clutch cover bolts evenly and in rota­
tion to relieve spring tension. Loosen the bolts a few
threads at a time only.
(3) Remove the cover bolts and remove the cover and
disc (Fig. 9).

CLUTCH COVER AND DISC INSTALLATION

(1) Check runout and free operation of the new clutch
disc. Install t h e disc on the transmission input shaft J8906-5
splines. The disc should slide freely on t h e splines.
Leave the disc on the shaft and check runout with a dial Fig. 9 Positioning Clutch Disc — Typical
6-12 CLUTCH , _ , . J

(8) Install the clutch housing/transmission/transfer
case as an assembly. See Group 21 Manual Transmis­
sion.
PILOT BEARING REPLACEMENT
(1) Remove the transmission/transfer case as an as­
sembly. See Group 21 Manual Transmission.
(2) Remove the clutch cover and disc.
(3) Remove the pilot bearing. Use an internal puller
and slide hammer if the bearing proves difficult to re­
move.
(4) Lubricate the new bearing with Mopar high tem­
perature wheel bearing grease.
(5) Insert the new bearing into the crankshaft by
hand, or with a clutch alignment tool or spare input
shaft (Fig. 10).
(6) Install the clutch disc and cover as outlined in this
section.
(7) Install the transmission/transfer case assembly.
(3) On XJ/MJ models, remove the instrument panel
lower trim cover for access to the cylinder push rod (Fig.
12).
(4) On YJ models, remove the cotter pin and washer
securing the cylinder push rod to the clutch pedal.
(5) On XJ/MJ models, remove the cotter pin and
washer securing the push rod to the pivot arm and slide
the rod off arm (Fig. 13).
(6) Remove the cylinder mounting bolts and nuts and
remove the cylinder. The cylinder bolts are reversed
REMOVE COVER
AND DRAIN FLUID
WITH SUCTION GUN

cardiagn.com
See Group 21 Manual Transmission.

CLUTCH MASTER CYLINDER REMOVAL

(1) Remove the master cylinder reservoir cap and
drain the fluid with a suction gun.
(2) Disconnect the hydraulic line at the cylinder (Fig.
11). Cap the line and cylinder to prevent dirt entry.

J8906-7

Fig. 11 Drain And Disconnect Clutch Master

Cylinder

REMOVE TRIM
COVER FOR ACCESS
TO CYLINDER v

PUSH ROD Ny

Fig. 10 Pilot Bearing Installation Fig. 12 Lower Trim Cover Position

 CLUTCH 6-13

(Fig. 14). Top bolt is installed from engine com­
partment. Bottom bolt is installed from p a s s e n g e r
compartment.
CLUTCH MASTER CYLINDER INSTALLATION
(1) Position the clutch master cylinder on the dash
panel and install the top attaching bolt.
(2) Install the cylinder bottom attaching bolt and the
both of the attaching bolt nuts. Tighten the nuts to 26
N*m(19 ft-lbs) torque.
(3) Connect the cylinder hydraulic line (Fig. 12).
Tighten the line fitting t o l 5 N*m (11 ft-lbs) torque.
(4) Install the cylinder push rod on the brake pedal or
pivot a r m and install the retaining washer and a new
cotter pin.
(5) Fill the cylinder reservoir with Mopar brake fluid,
or equivalent labeled SAE J-1703 or DOT 3 only.
(6) Install the reservoir cap and bleed the hydraulic
system.
CLUTCH MASTER CYLINDER OVERHAUL
Cylinder Disassembly and Cleaning
(1) Remove the reservoir cap.
(2) Pull the dust boot out of the cylinder groove.
(3) Press the cylinder plunger inward with the push
rod and unseat the push rod snap ring. Discard the snap
ring after removal. A new ring is included in the over­
haul kit.
(4) Remove the push rod, washer and dust boot (Fig.
15). Retain the push rod and washer but discard the dust

cardiagn.com
boot. A new boot is included in t h e overhaul kit.
(5) Remove the plunger, spring and valve stem as­
sembly (Fig. 15). Lightly tap the cylinder on a wood
block to dislodge the assembly. Discard the assembly
after removal.
(6) Clean the cylinder thoroughly with fresh brake
fluid or brake system cleaner only.

Cylinder Inspection and Assembly

(1) Inspect the cylinder bore for cracks, pitting, cor­
rosion, wear or scoring. Replace the cylinder if it ex­
hibits any of these conditions.
J8906-9 (2) Lubricate the cylinder bore with clean brake fluid.
(3) Lubricate the replacement valve, plunger and
Fig. 13 Push Rod Removal/Installation — XJ/MJ spring assembly with clean brake fluid.
(4) Install the new valve, plunger and spring assem­
CYLINDER CLUTCH MASTER
BRACKET AND bly in the cylinder bore.
LOWER BOLT CYLINDER
(5) Install the washer, snap ring and new dust boot on
UPPER UPPER
NUT BOLT the push rod.
(6) Lubricate ball end of the push rod with chassis
grease.
(7) Insert the push rod in the plunger. Press the
plunger inward and seat the washer and snap ring in
the cylinder bore.
(8) Install the dust boot on the cylinder. Be sure the
boot is seated in the cylinder boot groove.

HYDRAULIC CONCENTRIC BEARING

REPLACEMENT
The hydraulic concentric bearing is serviced as an
assembly only. The release bearing portion of the as­
LOWER NUT sembly is permanently attached to the piston. The hy­
draulic lines are also permanently attached.
The only time the concentric bearing assembly
J90064 should be replaced is w h e n it is either leaking or
Fig. 14 Clutch Master Cylinder Mounting Bolts obviously damaged. The bearing should never be
6 -14 CLUTCH J

cardiagn.com
© PUSH ROD © RESERVOIR CAP © RETAINER SPRING © PLUNGER FRONT SEAL
© DUST BOOT © RESERVOIR © SPRING RETAINER © PLUNGER
© SNAP RING © RETAINING CLAMP © PLUNGER SPRING @ VALVE STEM ASSEMBLY
© WASHER © STEM TIP SEAL © VALVE STEM RETAINER NOTE: ITEMS ©THROUGH ®
© CLUTCH MASTER CYLINDER © VALVE STEM © PLUNGER REAR SEAL ARE SUPPLIED AS AN ASSEMBLY.
J9006-5
Fig. 15 Clutch Master Cylinder Components

replaced just because the clutch disc or cover a r e
b e i n g serviced. R e p l a c e the b e a r i n g only w h e n it
has actually failed.
Concentric Bearing Removal
(1) Remove the clutch master cylinder reservoir cover
and drain the fluid with a suction gun. Reinstall the cap
afterward.
(2) Disconnect the clutch master cylinder line (Fig.
11). Cap the line to prevent dirt entry.
(3) Remove the clutch housing/transmission/transfer
case as an assembly. See Group 21 Manual Transmis­
sion.
(4) Disconnect the clutch master cylinder feed line.
(5) Remove the insulator plate bolts and slide the
plate and rubber insulator off the bleed line (Figs. 16
and 17).
(6) Remove the throwout bearing retaining n u t (Fig.
18). Pry the nut up and off the mounting pin on the
transmission case.
(7) Remove the concentric bearing from the transmis­
sion input shaft. If the bearing will be reused, secure the

INSULATOR CLUTCH
PLATE BLEED

RUBBER
INSULATOR

INSULATOR
PLATE CLUTCH
CYLINDER MASTER CLUTCH
LINE J9006-6 HOUSING J9006-7

Fig. 16 Insulator, Plate And Bleed Screw — 6-Cyl Fig. 17 Insulator, Plate And Bleed Screw — 4-Cyl
J CLUTCH
bearing and piston with tape or rubber bands. Or re­
connect the nylon straps if they are still usable.
Concentric Bearing installation
(1) New concentric bearings are equipped with nylon
retaining straps (Fig. 19).The straps hold the bearing
piston in place during shipment. It is not necessary to
cut the straps. Simply unhook the T-shaped ends from
the bearing before installation.
(2) Inspect the bearing mounting pin (Fig. 20). Re­
place the pin if damaged.
(3) Install the bearing assembly on the transmission
input shaft (Fig. 18).
(4) Guide the bearing inlet and bleed lines through
the openings in the clutch housing.
(5) Position the bearing boss on the mounting pin and
seat the bearing against the transmission case (Fig. 21).
(6) Secure the bearing to the mounting pin with a new
retaining nut (Fig. 21).
(7) Unhook the nylon straps t h a t secure the bearing
piston.
(8) Install the insulator and plate (Figs. 16, 17).
Fig. 18 Retaining Nut Removal/Installation
Fig. 19 Concentric Bearing Components
6-15
(9) Install the clutch housing/transmission/transfer
case assembly.
(10) Connect the c l u t d r m a s t e r cylinder fluid line.
(11) Fill and bleed the clutch hydraulic system.
CLUTCH SYSTEM BLEEDING
(1) Fill the clutch master cylinder with brake fluid.
(2) Raise the vehicle.
(3) Attach a bleed hose to the bleed screw on the
concentric bearing bleed, line (Figs. 16, 17).
(4) Insert the opposite end of the bleed hose in a glass
container partially filled with brake fluid. Be sure the
hose end is completely submerged in fluid.
(5) Carefully loosen the bleed screw. Hold the bleed
screw fitting firmly to prevent it from turning while
loosening the screw. Do not allow the b l e e d line to
b e n d or flex w h e n l o o s e n i n g the screw.
(6) Have a helper press and hold the clutch pedal to
the floor.
cardiagn.com
Fig. 20 Concentric Bearing Mounting Pin
Fig. 21 Concentric Bearing installation
6-16 CLUTCH
(7) Tighten the bleed screw and have helper release
the clutch pedal.
(8) Check clutch master cylinder fluid level. Add fluid*
if necessary. Do not allow the cylinder reservoir to run
out of fluid during bleedingoperations.
(9) Repeat the bleeding process until fluid entering
the glass container is free of bubbles. Be s u r e t h e b l e e d
h o s e e n d r e m a i n s s u b m e r g e d in b r a k e fluid d u r i n g
bleeding operations.
(10) Lower the vehicle.
(11) Top off the clutch master cylinder reservoir to
MAX indicator mark.
j
CLUTCH FLUID LEVEL
Fluid level is checked at the clutch master cylinder
reservoir (Fig. 3). Fluid level is indicated by the MAX
and MIN indicators on the cylinder reservoir. Check
and top off fluid level to the MAX mark. Do not allow
level to fall below the MIN mark.
The only fluid recommended for use in the clutch
hydraulic system is Mopar Brake Fluid, or equivalent
meeting SAE J-1703 and DOT 3 standards. Do not use
any any other type of fluid.
N e v e r u s e r e c l a i m e d b r a k e fluid o r fluid from a n
u n s e a l e d c o n t a i n e r . I n a d d i t i o n , d o n o t u s e fluid
from a c o n t a i n e r t h a t h a s b e e n o p e n e d a n d al­
l o w e d t o s t a n d for a n y l e n g t h of t i m e . M o i s t u r e in
t h e a i r c a n b e a b s o r b e d b y t h e fluid c a u s i n g dilu­
t i o n a n d loss of effectiveness.
cardiagn.com
J CLUTCH 6 -17

TORQUE SPECIFICATIONS

Component Foot Pounds N-m Inch Pounds N-m

Clutch Cover Bolts:

4-Cylinder 23 31
6-Cylinder 40 54

Concentric Bearing Fluid Fitting 132 15

Clutch Cylinder Mounting Bolts/Nuts 19 26

Clutch Cylinder Hydraulic Line Fitting:

4-Cylinder 132 15

6-Cylinder 190 21

cardiagn.com
Clutch Housing-to-Engine Bolts:
Ml 2x1.75 55 75

3/8-16 27 37

7/16-14 43 58

Clutch Housing Cover (4-Cylinder):

Upper Bolt 16 22
Lower Bolt 55 75

Clutch Housing-to-Transmission Bolt:

AX 15 28 38
AX 5 28 38

Starter Motor Dowel Bolt 33 45

U-Joint Clamp Bolts 170 19 |

Rear Support-to-Crossmember Bolt 33 45

Crossmember-to-Frame Rail Bolt 30 41

J9006-18
cardiagn.com