Clutch Component Lubrication; Clutch Fluid Level; Clutch Linkage Fluid; Flywheel - Jeep Wrangler 1999 Electronic Service Manual

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SERVICE PROCEDURES

CLUTCH COMPONENT LUBRICATION

Proper clutch component lubrication is important
to satisfactory operation. Using the correct lubricant
and not over lubricating are equally important. Apply
recommended lubricant sparingly to avoid disc and
pressure plate contamination.
Clutch and transmission components requiring
lubrication are:
• Pilot bearing.
• Release lever pivot ball stud.
• Release lever contact surfaces.
• Release bearing bore.
• Clutch disc hub splines.
• Clutch pedal pivot shaft bore.
• Clutch pedal bushings.
• Input shaft splines.
• Input shaft pilot hub.
• Transmission front bearing retainer slide sur-
face.
NOTE: Never apply grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar multi-purpose grease for the clutch
pedal bushings and pivot shaft. Use Mopar
temperature grease (or equivalent) for all other lubri-
cation requirements. Apply recommended amounts
and do not over lubricate.

CLUTCH LINKAGE FLUID

If inspection or diagnosis indicates additional fluid
may be needed, use Mopar brake fluid, or an equiv-
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. The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling, or remov-
ing fluid from the reservoir.
Clutch fluid level is checked at the master cylinder
reservoir (Fig. 3). An indicator ring is provided on the
outside of the reservoir. With the cap and diaphragm
removed, fluid level should not be above indicator ring.
To avoid contaminating the hydraulic fluid during
inspection, wipe reservoir and cover clean before
removing the cap.
Fig. 3 Clutch Master Cylinder Reservoir And Cap

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-
high
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 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
CLUTCH 6 - 9