Clutch Cover And Disc; Removal And Installation - Jeep Wrangler 1997 Manual

6-10 CLUTCH
SERVICE PROCEDURES (Continued)
cator on a stud installed in place of one of the
flywheel 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 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
" 68 N-m (50 ft. lbs.) plus an additional turn of
60° 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 resistant 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.
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 .
TJ
(6) Be sure to wear eye and hand protection. Heat
resistant 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. 4) .
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. 4) . 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. 4) . Replace cover if this surface is
worn, heat checked, cracked, or scored .