Clutch Release Cylinder-Removal, Overhaul And Installation; Clutch Release Cylinder Internal Components; Clutch Hydraulic System-Bleeding - Jeep cherokee 1989 Owner's Manual

Installation
26 Position the cylinder against the firewall and install the lower
mounting nut, but don't tighten it fully yet.
27 Connect the hydraulic line t o the cylinder, tightening the fitting
by hand only. Since the cylinder is still loose,
slightly to make it easier to align the fitting threads.
28 lnstall the upper mounting bolt, again using an assistant to tighten
the bolt while the nut is held stationary.
29 Connect the pushrod to the clutch pedal, install the washers and
a new cotter pin.
3 0 Tighten the lower mounting nut.
31 Tighten the hydraulic line fitting securely.
3 2 lnstall the fluid reservoir if
it
3 3 Fill the reservoir with brake fluid conforming t o DOT 3 specifica-
tions and bleed the system as described in Section 8.
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7 Clutch release cylinder removal, overhaul and installation
Note: This procedure applies to externally mounted release cylinders
only (the hydraulic release bearing mounted inside the clutch housing
is not serviceable). Before beginning this procedure, contact local parts
stores and dealer service departments concerning the purchase of a
rebuild kit or a new release cylinder. Availability and cost of the
necessary parts may dictate whether the cylinder is rebuilt or replaced
with a new one. If it's decided to rebuild the cylinder, inspect the bore
as described in Step 8 before purchasing parts.
Removal
1 Disconnect the negative cable from the battery.
2
Raise the vehicle and support it securely on jackstands.
3 Disconnect the hydraulic line at the release cylinder. If available,
use a flare nut wrench on the fitting, which will prevent the fitting from
being rounded off. Have a small can and rags handy, as some fluid
will be spilled as the line is removed.
4 Remove the t w o release cylinder mounting bolts.
5
Remove the release cylinder.
Overhaul
Refer to illustration 7.7
6 Separate the rubber boot from the cylinder.
7 Pull the pushrod, boot, plunger and spring from the cylinder (see
illustration).
8
Carefully inspect the bore of the cylinder. Check for deep scratches,
score marks and ridges. The bore must be smooth to the touch. If any
imperfections are found, the release cylinder must be replaced with
a new one.
9 Using the new parts in the rebuild kit, assemble the components
using plenty of fresh brake fluid for lubrication. Note the installed direc-
tion of the spring and the seal (the seal lips must point toward the
spring).
4
7 . 7

Clutch release cylinder internal components

1 Boot
2 Pushrod
3 Plunger
The Motor Manual Guy
8
Chapter Clutch and drivetrain
can be wiggled around
it
was previously removed.
3
I
2
4 Spring
5 Seal
8.5 Location of the bleeder screw (arrow) on models with
a hydraulic clutch release bearing
lnstallation
1 0 Install the release cylinder on the clutch housing. Make sure the
1 1 Connect the hydraulic line to the release cylinder. Tighten the fitting
1 2 Fill the clutch master cylinder with brake fluid conforming to DOT 3
specifications.
1 3 Bleed the system as described in Section 8.
1 4 Lower the vehicle and connect the negative battery cable.
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8 Clutch hydraulic system
Refer to illustration 8.5
1 The hydraulic system should be bled to remove all air whenever
any part of the system has been removed or if the fluid level has fallen
so low that air has been drawn into the master cylinder. The procedure
is very similar to bleeding a brake system.
2 Fill the master cylinder with new brake fluid conforming to DOT 3
specifications. Caution: Don't re-use any of the fluid coming from the
system during the bleeding operation. Also, don't use fluid which has
been inside an open container for an extended period of time.
3 Raise the vehicle and place
it
to the release cylinder (or bleeder screw), which is located on the left
side of the clutch housing.
4 On models with an externally mounted release cylinder, remove
the t w o release cylinder mounting bolts and pull the cylinder from the
clutch housing. Remove the pushrod from the cylinder, then compress
the plunger into the cylinder with a universal gear puller or a C-clamp
and socket.
5 Remove the dust cap which fits over the bleeder screw (see illustra-
tion) and push a length of plastic hose over the screw. Place the other
end of the hose in a clear container with about t w o inches of brake
fluid. The hose end must be in the fluid at the bottom of the container.
6 Have an assistant depress the clutch pedal and hold
bleeder screw on the release cylinder, allowing fluid to flow through
the hose. Close the bleeder screw when the flow of bubbles or old
fluid ceases. Once closed, have your assistant release the pedal.
7 Continue this process until all air is evacuated from the system,
indicated by a solid stream of fluid being ejected from the bleeder screw
each time with no air bubbles in the hose or container. Keep a close
watch on the fluid level inside the master cylinder
too low, air will be sucked back into the system and the process will
have to be started all over again.
8 lnstall the pushrod, mount the release cylinder (externally mounted
cylinder only) and lower the vehicle. Top off the fluid level and check
carefully for proper operation before placing the vehicle in normal
service.
bleeding
securely on jackstands to gain access
Open the
it.
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if the level drops