Jeep Cherokee 2000, Service Manual

Page: 220 / 1528

alent meeting standards SAE J1703 and DOT 3. Do
not use any other type of fluid.
CLUTCH FLUID LEVEL
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are pre-filled with fluid at
the factory during assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances. In fact, the reser-
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir.
Clutch fluid level is checked at the master cylinder
reservoir (Fig. 9). An indicator ring is provided on the
outside rim of the reservoir.
Be sure to wipe the reservoir and cover clean
before removing the cover. This will avoid having dirt
or foreign material fall into the reservoir during a
fluid level check.
FLYWHEEL
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
Minor scratches, burrs, 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 machining is not recommended. The fly-
wheel surface is manufactured with a unique contour
that would be negated by machining. However,
cleanup of minor flywheel scoring can be performed
by hand with 180 grit emery, or with surface grind-
ing equipment. Replace the flywheel if scoring is
deeper than 0.0762 mm (0.003 in.).
Heavy stock removal by grinding is not recom-
mended. Excessive stock removal can result in fly-
wheel cracking or warpage after installation. It can
also weaken the flywheel and interfere with proper
clutch release.
Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the fly-
wheel face with a dial indicator. Mount the dial indi-
cator on a stud installed in place of one of the clutch
housing attaching bolts.
Clean the crankshaft flange before mounting the
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
t
Lock N’ Seal, or Loctite
242 on the replacement bolt threads.
Recommended flywheel bolt torques are:
•
142 N·m (105 ft. lbs.) for 6-cylinder flywheels
•
95 N·m (70 ft. lbs.) for 4-cylinder flywheels
Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
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-
erence on the flywheel. Use a scriber for this pur-
pose.
(2) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han-
dling a heated ring gear.
(3) Remove the old gear by cutting most of the way
through it (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or
punch.
(4) The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating in
order to install it. The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the same
time to produce uniform expansion. An oven or simi-
lar enclosed heating device must be used. Tempera-
ture required for uniform expansion is approximately
375° F.
Fig. 9 Clutch Master Cylinder Reservoir And Cap
1 – CAP
2 – FILL LINE
3 – CLUTCH MASTER CYLINDER
4 – RESERVOIR
6 - 10 CLUTCH
XJ
SERVICE PROCEDURES (Continued)