Removal And Installa Tion; Clutch Cover And Disc - Jeep Cherokee 1999 Electronic Service Manual

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SERV I CE PROCEDU RES (Cont inue d)
• 68 N·m (50 ft . lbs.) plu s a n a ddit ion a l t u r n of
60° for 4-cylin der flywh eels
In spect t h e t eet h on t h e st a r t er r in g gea r. If th e
te e th a re w o rn o r d a m a g e d , th e fly w h e e l s h o u ld
be re p la c e d a s a n a s s e m bly. Th is is th e re c o m -
m e n d e d a n d p re fe rre d m e th o d o f re p a ir.
In ca ses wh er e a n ew flywh eel is n ot r ea dily a va il-
a ble, a r epla cem en t r in g gea r ca n be in st a lled. H ow-
ever, t h e followin g pr eca u t ion s m u st be obser ved t o
a void da m a gin g t h e flywh eel a n d r epla cem en t gea r.
(1) Ma r k posit ion of t h e old gea r for a lign m en t r ef-
er en ce on t h e flywh eel. Use a scr iber for t h is pu r-
pose.
(2) Wea r pr ot ect ive goggles or a ppr oved sa fet y
gla sses. Also wea r h ea t r esist en t gloves wh en h a n -
dlin g a h ea t ed r in g gea r.
(3) Rem ove t h e old gea r by cu t t in g m ost of t h e wa y
t h r ou gh it (a t on e poin t ) wit h a n a br a sive cu t -off
wh eel. Th en com plet e r em ova l wit h a cold ch isel or
pu n ch .
(4) Th e r in g gea r is a sh r in k fit on t h e flywh eel.
Th is m ea n s t h e gea r m u st be expa n ded by h ea t in g in
or der t o in st a ll it . Th e m e th o d o f h e a tin g a n d
e x p a n d in g th e g e a r is e x tre m e ly im p o rta n t.
E ver y su r fa ce of t h e gea r m u st be h ea t ed a t t h e sa m e
t im e t o pr odu ce u n ifor m expa n sion . An oven or sim i-
la r en closed h ea t in g device m u st be u sed. Tem per a -
t u r e r equ ir ed for u n ifor m expa n sion is a ppr oxim a t ely
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
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(5) Th e h ea t ed gea r m u st be in st a lled even ly t o
a void m isa lign m en t or dist or t ion . A sh op pr ess a n d
su it a ble pr ess pla t es sh ou ld be u sed t o in st a ll t h e
gea r if a t a ll possible.
(6) Be su r e t o wea r eye a n d h a n d pr ot ect ion . H ea t
r esist en t gloves a n d sa fet y goggles a r e n eeded for
per son a l sa fet y. Also u se m et a l t on gs, vise gr ips, or
sim ila r t ools t o posit ion t h e gea r a s n ecessa r y for
in st a lla t ion .
(7) Allow t h e flywh eel a n d r in g gea r t o cool down
befor e in st a lla t ion . Set t h e a ssem bly on a wor kben ch
a n d let it cool in n or m a l sh op a ir.
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.
uneven heating and
REM OVAL AN D I N STALLAT I ON

CLUTCH COVER AND DISC

REMOVAL
(1) Rem ove t r a n sm ission . Refer t o pr ocedu r es in
Gr ou p 21.
(2) If or igin a l clu t ch cover will be r ein st a lled, m a r k
posit ion of cover on flywh eel for a ssem bly r efer en ce.
Use pa in t or a scr iber for t h is pu r pose.
(3) If clu t ch cover is t o be r epla ced, cover bolt s ca n
be r em oved in a n y sequ en ce. H owever, if or igin a l
cover will be r ein st a lled, loosen cover bolt s even ly
a n d in r ot a t ion t o r elieve spr in g t en sion equ a lly. Th is
is n ecessa r y t o a void wa r pin g cover.
(4) Rem ove cover bolt s a n d r em ove cover a n d disc
(F ig. 2).
INSTALLA TION
(1) Ligh t ly scu ff sa n d flywh eel fa ce wit h 180 gr it
em er y clot h . Th en clea n su r fa ce wit h a wa x a n d
gr ea se r em over.
(2) Lu br ica t e pilot bea r in g wit h Mopa r h igh t em -
per a t u r e bea r in g gr ea se.
(3) Ch eck r u n ou t a n d fr ee oper a t ion of n ew clu t ch
disc a s follows:
(a ) Slide disc on t o t r a n sm ission in pu t sh a ft
splin es. Disc sh ou ld slide fr eely on splin es.
(b) Lea ve disc on sh a ft a n d ch eck fa ce r u n ou t
wit h dia l in dica t or. Ch eck r u n ou t a t disc h u b a n d
a bou t 6 m m (1/4 in .) fr om ou t er edge of fa cin g.
(c) F a ce r u n ou t sh ou ld n ot exceed 0.5 m m (0.020
in .). Obt a in a n ot h er clu t ch disc if r u n ou t exceeds
t h is lim it .
(4) P osit ion clu t ch disc on flywh eel. Be su r e side of
disc m a r ked flywh eel side is posit ion ed a ga in st fly-
wh eel (F ig. 2). If disc is n ot m a r ked, be su r e fla t side
of disc h u b is t owa r d flywh eel.
(5) In spect con dit ion of pr essu r e pla t e su r fa ce of
clu t ch cover (F ig. 2). Repla ce cover if t h is su r fa ce is
wor n , h ea t ch ecked, cr a cked, or scor ed.
(6) In ser t clu t ch a lign m en t t ool in clu t ch disc (F ig.
3).
(7) In ser t a lign m en t t ool in pilot bea r in g a n d posi-
t ion disc on flywh eel. Be su r e disc h u b is posit ion ed
cor r ect ly. Side of h u b m a r ked F lywh eel Side sh ou ld
fa ce flywh eel (F ig. 2). If disc is n ot m a r ked, pla ce fla t
side of disc a ga in st flywh eel.
(8) P osit ion clu t ch cover over disc a n d on flywh eel
(F ig. 3).
(9) In st a ll clu t ch cover bolt s fin ger t igh t .
(10) Tigh t en cover bolt s even ly a n d in r ot a t ion a
few t h r ea ds a t a t im e. Co v e r bo lts m u s t be tig h t-
e n e d e v e n ly a n d to s p e c ifie d to rqu e to a v o id
d is to rtin g c o v e r. Tig h te n in g to rqu e s a re 31 N ·m
CLUTCH 6 - 9