Jeep 200 Cherokee Service Manual page 233

6 - 8 CLUTCH
DIAGNOSIS AND TESTING (Continued)
CONDITION
Facing on flywheel side of disc torn,
gouged, or worn.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
Clutch disc binds on input shaft
splines.
Clutch disc rusted to flywheel and/or
pressure plate.
Pilot bearing seized, loose, or rollers
are worn.
Clutch will not disengage properly.
POSSIBLE CAUSES
1. Flywheel surface scored or
nicked.
2. Clutch disc sticking or binding on
transmission input shaft.
1. Frequent operation under high
loads or hard acceleration
conditions.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
1. Clutch disc hub splines damaged
during installation.
2. Input shaft splines rough,
damaged, or corroded.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Bearing cocked during
installation.
2. Bearing defective.
3. Bearing not lubricated.
4. Clutch misalignment.
1. Low clutch fluid level.
2. Clutch cover loose.
3. Clutch disc bent or distorted.
4. Clutch cover diaphragm spring
bent or warped.
5. Clutch disc installed backwards.
6. Release fork bent or fork pivot
loose or damaged.
7. Clutch master or slave cylinder
failure.
CORRECTION
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Inspect components and
correct/replace as necessary.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
1. Install and lubricate a new
bearing.
2. Install and lubricate a new
bearing.
3. Install and lubricate a new
bearing.
4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
1. Replace hydraulic linkage
assembly.
2. Follow proper bolt tightening
procedure.
3. Replace clutch disc.
4. Replace clutch cover.
5. Remove and install clutch disc
correctly.
6. Replace fork or pivot as
necessary.
7. Replace hydraulic linkage
assembly.
XJ