Jeep 200 Cherokee, Service Manual

Page: 236 / 2119

CAUTION: Do not use an oxy/acetylene torch to
remove 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.
(5) 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.
(6) 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.
(7) Allow the flywheel and ring gear to cool down
before installation. Set the assembly on a workbench
and let it cool in normal shop air.
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.
REMOVAL AND INSTALLATION
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 to avoid warping cover.
(4) Remove cover bolts and remove cover and disc
(Fig. 10).
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.
(4) Position clutch disc on flywheel. Be sure side of
disc marked flywheel side is positioned against fly-
wheel (Fig. 10). If disc is not marked, be sure flat
side of disc hub is toward flywheel.
(5) Inspect condition of pressure plate surface of
clutch cover (Fig. 10). Replace cover if this surface is
worn, heat checked, cracked, or scored.
(6) Insert clutch alignment tool in clutch disc (Fig.
11).
(7) Insert alignment tool in pilot bearing and posi-
tion disc on flywheel. Be sure disc hub is positioned
correctly. Side of hub marked Flywheel Side should
face flywheel (Fig. 10). If disc is not marked, place
flat side of disc against flywheel.
(8) Position clutch cover over disc and on flywheel
(Fig. 11).
(9) Install clutch cover bolts finger tight.
(10) Tighten cover bolts evenly and in rotation a
few threads at a time. Cover bolts must be tight-
ened evenly and to specified torque to avoid
distorting cover. Tightening torques are 31 N·m
(23 ft. lbs.) on 2.5L engines and 50N·m (37ft. lbs.)
on 4.0 L engines.
(a) Start all 6 bolts by hand.
(b) Tighten 3 pilot hole bolts 3/4s of the way
(any sequence).
Fig. 10 Clutch Disc And Pressure Plate Inspection
1 – DISC
2 – INSPECT THIS SURFACE
3 – CLUTCH COVER
4 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE
XJ
CLUTCH 6 - 11
SERVICE PROCEDURES (Continued)