1. XJ CLUTCH 6-1
CLUTCH
CONTENTS
page page
GENERAL INFORMATION IMPROPER CLUTCH RELEASE OR
CLUTCH COMPONENTS . . . . . . . . . . . ....... 1 ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3
CLUTCH HYDRAULIC FLUID . . . . . . . . ....... 2 MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH LUBRICATION . . . . . . . . . . . . ....... 2 SERVICE PROCEDURES
INSTALLATION METHODS AND PARTS CLUTCH COMPONENT LUBRICATION . . . . . . . 5
USAGE . . . . . . . . . . . . . . . . . . . . . . . ....... 2 CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 10
SAFETY PRECAUTIONS . . . . . . . . . . . ....... 1 CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH OPERATION . . . . . . . . . . . . . ....... 2 REMOVAL AND INSTALLATION
DIAGNOSIS AND TESTING CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 11
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . . 3 CLUTCH HOUSING REPLACEMENT—AX15 . . 12
CLUTCH RUNOUT . . . . . . . . . . . . . . . . . . . . . . . 3 CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 14
DIAGNOSTIC CHARTS . . . . . . . . . . . . . . . . . . . 5 PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 3 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION connected to the clutch release fork. The master cyl-
inder is mounted on the driver side of the dash panel
CLUTCH COMPONENTS adjacent to the brake master cylinder and booster
The clutch mechanism consists of a single, dry-type assembly. This positioning is similar for both left and
disc and a diaphragm style clutch cover. A hydraulic right hand drive models.
linkage is used to operate the clutch release bearing
and fork. SAFETY PRECAUTIONS
A needle-type pilot bearing in the crankshaft
flange supports the transmission input shaft. A WARNING: EXERCISE CARE WHEN SERVICING
sleeve type release bearing is used to engage and dis- CLUTCH COMPONENTS. FACTORY INSTALLED
engage the clutch cover pressure plate. CLUTCH DISCS DO NOT CONTAIN ASBESTOS
The release bearing is operated by a release fork in FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
the clutch housing. The fork pivots on a ball stud CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
mounted in the housing. The release fork is actuated KET COMPONENTS. BREATHING EXCESSIVE CON-
by a hydraulic slave cylinder mounted in the hous- CENTRATIONS OF THESE FIBERS CAN CAUSE
ing. The slave cylinder is operated by a clutch master SERIOUS BODILY HARM. WEAR A RESPIRATOR
cylinder mounted on the dash panel. The cylinder DURING SERVICE AND NEVER CLEAN CLUTCH
push rod is connected to the clutch pedal. COMPONENTS WITH COMPRESSED AIR OR WITH
The clutch disc has cushion springs in the disc A DRY BRUSH. EITHER CLEAN THE COMPONENTS
hub. The clutch disc facing is riveted to the hub. The WITH A WATER DAMPENED RAGS OR USE A VAC-
facing is made from a non-asbestos material. The UUM CLEANER SPECIFICALLY DESIGNED FOR
clutch cover pressure plate is a diaphragm type with REMOVING ASBESTOS FIBERS AND DUST. DO NOT
a one-piece spring and multiple release fingers. The CREATE DUST BY SANDING A CLUTCH DISC.
pressure plate release fingers are preset during man- REPLACE THE DISC IF THE FRICTION MATERIAL IS
ufacture and are not adjustable. DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
HYDRAULIC LINKAGE COMPONENTS IN SEALED BAGS OR CONTAINERS. THIS WILL
The hydraulic linkage consists of a clutch master HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
cylinder with integral reservoir, a clutch slave cylin- OTHERS. FOLLOW ALL RECOMMENDED SAFETY
der and an interconnecting fluid line. PRACTICES PRESCRIBED BY THE OCCUPATIONAL
The clutch master cylinder push rod is connected SAFETY AND HEALTH ADMINISTRATION (OSHA)
to the clutch pedal. The slave cylinder push rod is AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.

2. 6-2 CLUTCH XJ
GENERAL INFORMATION (Continued)
CLUTCH HYDRAULIC FLUID A cocked pilot bearing is another cause of clutch
The clutch hydraulic linkage cylinders and lines noise, drag, hard shifting, and rapid bearing wear.
are prefilled with fluid at the factory. Always use an alignment tool to install a new bear-
The hydraulic system should not require additional ing. This practice helps avoid cocking the bearing
fluid under normal circumstances. In fact, the reser- during installation.
voir fluid level will actually increase as normal clutch
wear occurs. For this reason, it is important to avoid
DESCRIPTION AND OPERATION
overfilling, or removing fluid from the reservoir. This
action will cause clutch release problems.
CLUTCH OPERATION
If inspection or diagnosis indicates additional fluid
Leverage, clamping force, and friction are what
may be needed, use Mopar௡ brake fluid, or an equiv-
make the clutch work. The disc serves as the friction
alent, meeting SAE J1703 and DOT 3 standards. Do
element and a diaphragm spring and pressure plate
not use any other type of fluid.
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
CLUTCH LUBRICATION
leverage.
Proper clutch component lubrication is important
The clutch cover assembly clamps the disc against
to satisfactory operation. Using the correct lubricant
the flywheel. The assembly consists of the cover, dia-
and avoiding over lubrication are also equally impor-
phragm spring, pressure plate, and fulcrum compo-
tant.
nents. The pressure plate clamps the clutch disc
During service, apply recommended lubricant spar-
against the flywheel and the spring provides the
ingly. Do not overlubricate as this could result in
clamping force.
clutch disc and pressure plate contamination.
The clutch disc friction material is riveted to the
Clutch and transmission components requiring
disc hub. The hub bore is splined for installation on
lubrication are:
the transmission input shaft. The hub splines con-
• pilot bearing.
nect the disc to the transmission.
• release lever pivot ball stud.
The clutch linkage uses hydraulic pressure to oper-
• release lever pivot surfaces.
ate the clutch. The clutch master cylinder push rod is
• release bearing bore.
connected to the clutch pedal and the slave cylinder
• clutch pedal pivot bore and bushings.
push rod is connected to the release lever in the
• transmission input shaft splines and pilot hub.
clutch housing.
• release bearing slide surface of front bearing
Depressing the clutch pedal develops fluid pressure
retainer.
in the clutch master cylinder. This pressure is trans-
Do not apply grease to any part of the clutch
mitted to the slave cylinder through a connecting
cover or disc.
line. In turn, the slave cylinder operates the clutch
Use Mopar௡ multi-mileage grease or a silicone
release lever.
grease for the clutch pedal bushings and pivot shaft.
The clutch release bearing is mounted on the
Use Mopar௡ high temperature bearing grease or
transmission front bearing retainer. The bearing is
equivalent for the pilot bearing, release bearing bore,
attached to the release lever, which moves the bear-
transmission input shaft and release fork compo-
ing into contact with the clutch cover diaphragm
nents. Apply recommended amounts only and do not
spring.
overlubricate.
Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
INSTALLATION METHODS AND PARTS USAGE
phragm spring. As additional force is applied, the
Distortion of clutch components during installation
bearing presses the diaphragm spring fingers inward
and the use of non-standard components are common
on the fulcrums. This action moves the pressure
causes of clutch malfunction.
plate rearward relieving clamp force on the disc. The
Improper clutch cover bolt tightening can distort
clutch disc is disengaged and freewheeling at this
the cover. The usual result is clutch grab, chatter
point.
and rapid wear.
The process of clutch re-engagement is simply the
An improperly seated flywheel and/or clutch hous-
reverse of what occurs during disengagement. Releas-
ing are additional causes of clutch failure. Improper
ing pedal pressure removes clutch linkage pressure.
seating will produce misalignment and additional
The release bearing moves away from the diaphragm
clutch problems.
spring which allows the pressure plate to exert
The use of non-standard or low quality parts will
clamping force on the clutch disc.
also lead to problems and wear. Use recommended
factory parts only.

3. XJ CLUTCH 6-3
DIAGNOSIS AND TESTING nents. A visual inspection of the release components
will usually reveal the problem part.
GENERAL INFORMATION Release problems can result in hard shifting and
Problem diagnosis will generally require a road noise. Items to look for are: leaks at the clutch cylin-
test to determine the type of fault. Component ders and interconnecting line; loose slave cylinder
inspection will then determine the problem cause bolts; worn/loose release fork and pivot stud; dam-
after road testing. aged release bearing; and a worn clutch disc, or pres-
Drive the vehicle at normal speeds during the road sure plate.
test. Shift the transmission through all gear ranges Normal condensation in vehicles that are stored or
and observe clutch action. out of service for long periods of time can generate
If chatter, grab, slip, or improper release is experi- enough corrosion to make the disc stick to the flywheel,
enced, remove and inspect the clutch components. or pressure plate. If this condition is experienced, cor-
However, if the problem is noise or hard shifting, fur- rection only requires that the disc be loosened manu-
ther diagnosis may be needed. The transmission or ally through the inspection plate opening.
another driveline component may actually be at Engagement problems usually result in slip, chat-
fault. Careful observation during the test will help ter/shudder, and noisy operation. The primary causes
narrow the problem area. are clutch disc contamination; clutch disc wear; mis-
alignment, or distortion; flywheel damage; or a com-
CLUTCH CONTAMINATION bination of the foregoing. A visual inspection is
Fluid contamination is a frequent cause of clutch required to determine the part actually causing the
malfunctions. Oil, grease, water, or other fluids on problem.
the clutch contact surfaces will cause faulty opera-
tion. The usual result is chatter, slip and grab. CLUTCH RUNOUT
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, clutch CLUTCH DISC
hydraulic fluid, or water/road splash on clutch com- Check the clutch disc before installation. Axial
ponents. (face) runout of a new disc should not exceed 0.5 mm
Oil contamination indicates a leak at either the (0.020 in.). Measure runout about 6 mm (1/4 in.) from
rear main seal or transmission input shaft. Oil leaks the outer edge of the disc facing. Obtain another disc
produce a residue of oil on the housing interior and if runout is excessive.
on the clutch cover and flywheel. Heat buildup
CLUTCH COVER
caused by slippage between the clutch cover, disc,
Check condition of the clutch cover before installa-
and flywheel can sometimes bake the oil residue onto
tion. A warped cover or diaphragm spring will cause
the components. The glaze-like residue ranges in
grab and incomplete release or engagement. Be care-
color from amber to black.
ful when handling the cover and disc. Impact can dis-
Road splash contamination means dirt/water is
tort the cover, diaphragm spring, release fingers and
entering the clutch housing. This may be due to loose
the hub of the clutch disc.
bolts, housing cracks, or through the slave cylinder
Use an alignment tool when positioning the disc on
opening. Driving through deep water puddles can
the flywheel. The tool prevents accidental misalign-
force water/road splash into the housing through
ment which could result in cover distortion and disc
such openings.
damage.
Clutch fluid leaks are from loose or damaged
A frequent cause of clutch cover distortion is
clutch linkage fluid lines or connections. However,
improper bolt tightening. To avoid warping the cover,
most clutch fluid leaks will usually be noted and cor-
the bolts must be tightened in a diagonal pattern and
rected before severe contamination occurs.
only 2–3 threads at a time to the specified torque.
Grease contamination is usually a product of exces-
sive lubrication during clutch service. Apply only a FLYWHEEL
small amount of grease to the input shaft splines, Flywheel runout should not exceed 0.08 mm (0.003
bearing retainer, pilot bearing, release fork and pivot in.). Measure runout at the outer edge of the fly-
stud. Excess grease can be thrown off during opera- wheel face with a dial indicator. Mount the indicator
tion and contaminate the disc. on a stud installed in place of one of the flywheel
bolts.
IMPROPER CLUTCH RELEASE OR ENGAGEMENT Common causes of runout are:
Clutch release or engagement problems are caused • heat warpage.
by wear, or damage to one or more clutch compo- • improper machining.

4. 6-4 CLUTCH XJ
DIAGNOSIS AND TESTING (Continued)
9 Inspect release bearing slide surface of trans.
front bearing retainer. Surface should be smooth,
free of nicks, scores. Replace retainer if
necessary. Lubricate slide surface before
installing release bearing.
10 Do not replace release bearing unless actually
faulty. Replace bearing only if seized, noisy, or
damaged.
11 Check clutch cover diaphragm spring and release
fingers. Replace cover if spring or fingers are
bent, warped, broken, cracked. Do not tamper
with factory spring setting as clutch problems will
result.
12 Check condition of clutch cover. Replace clutch
cover if plate surface is deeply scored. warped,
worn, or cracked. Be sure cover is correct size
and properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.
Replace housing if damaged.
14 Verify that housing alignment dowels are in
position before installing housing.
15 Clean engine block surface before installing
clutch housing. Dirt, grime can produce
misalignment.
1 Check clutch housing bolts. Tighten if loose. Be
sure housing is fully seated on engine block. 16 Make sure side of clutch disc marked “flywheel
side” is toward flywheel.
2 Check flywheel. Scuff sand face to remove glaze.
Clean surface with wax and grease remover. 17 Check rear main seal if clutch disc and cover were
Replace flywheel if severely scored, worn or oil covered. Replace seal if necessary.
cracked. Secure flywheel with new bolts (if 18 Check crankshaft flange (if flywheel is removed).
removed). Do not reuse old bolts. Use Mopar Be sure flance is clean and flywheel bolt threads
Lock N’Seal on bolts. are in good condition.
3 Tighten clutch cover bolts 2-3 threads at a time, 19 Check pilot bearing. Replace bearing if damaged.
alternately and evenly (in a star pattern) to Lube with Mopar high temp. bearing grease
specified torque. Failure to do so could wrap the before installation.
cover.
20 Check transmission input shaft. Disc must slide
4 Check release fork. Replace fork if bent or worn. freely on shaft splines. Lightly grease splines
Make sure pivot and bearing contact surfaces are before installation. Replace shaft if splines or pilot
lubricated. bearing hub are damaged.
5 Check release fork pivot (in housing). Be sure 21 Check flywheel bolt torque. If bolts are loose,
pivot is suecure and ball end is lubricated. replace them. Use Mopar Lock N’Seal to secure
6 Transmission input shaft bearing will cause noise, new bolts.
chatter, or improper release if damaged. Check 22 Check clutch disc facing. Replace disc if facing is
condition before installing transmission. charred, scored, flaking off, or worn. Also check
7 Check slave cylinder. Replace it if leaking. Be runout of new disc. Runout should not exceed 0.5
sure cylinder is properly secured in housing and mm (0.02 in.).
cylinder piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc
were oil covered. Replace seal if worn, or cut.
Clutch Components

5. XJ CLUTCH 6-5
DIAGNOSIS AND TESTING (Continued)
• incorrect bolt tightening. SERVICE PROCEDURES
• improper seating on crankshaft flange shoulder.
• foreign material on crankshaft flange. CLUTCH COMPONENT LUBRICATION
Flywheel machining is not recommended. The fly- Proper clutch component lubrication is important
wheel clutch surface is machined to a unique contour to satisfactory operation. Using the correct lubricant
and machining will negate this feature. However, and not over lubricating are equally important. Apply
minor flywheel scoring can be cleaned up by hand recommended lubricant sparingly to avoid disc and
with 180 grit emery, or with surface grinding equip- pressure plate contamination.
ment. Remove only enough material to reduce scor- Clutch and transmission components requiring
ing (approximately 0.001 - 0.003 in.). Heavy stock lubrication are:
removal is not recommended. Replace the flywheel • Pilot bearing.
if scoring is severe and deeper than 0.076 mm (0.003 • Release lever pivot ball stud.
in.). Excessive stock removal can result in flywheel • Release lever contact surfaces.
cracking or warpage after installation; it can also • Release bearing bore.
weaken the flywheel and interfere with proper clutch • Clutch disc hub splines.
release. • Clutch pedal pivot shaft bore.
Clean the crankshaft flange before mounting the • Clutch pedal bushings.
flywheel. Dirt and grease on the flange surface may • Input shaft splines.
cock the flywheel causing excessive runout. Use new • Input shaft pilot hub.
bolts when remounting a flywheel and secure the • Transmission front bearing retainer slide sur-
bolts with Mopar௡ Lock And Seal. Tighten flywheel face.
bolts to specified torque only. Overtightening can dis-
tort the flywheel hub causing runout. NOTE: Never apply grease to any part of the clutch
cover, or disc.
MISALIGNMENT
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment RECOMMENDED LUBRICANTS
between the crankshaft and transmission input Use Mopar௡ multi-purpose grease for the clutch
shaft. Misalignment can cause clutch noise, hard pedal bushings and pivot shaft. Use Mopar௡ high
shifting, incomplete release and chatter. It can also temperature grease (or equivalent) for all other lubri-
result in premature wear of the pilot bearing, cover cation requirements. Apply recommended amounts
release fingers and clutch disc. In severe cases, mis- and do not over lubricate.
alignment can also cause premature wear of the
transmission input shaft and front bearing. CLUTCH LINKAGE FLUID
Housing misalignment is generally caused by The integral clutch master cylinder reservoir, slave
incorrect seating on the engine or transmission, loose cylinder and fluid lines are pre-filled with fluid prior
housing bolts, missing alignment dowels, or housing to assembly operations.
damage. Tighten all the clutch housing bolts to The hydraulic system should not require additional
proper torque before installing any struts. Also be fluid under normal circumstances. In fact, the reser-
sure alignment dowels are in place and seated in the voir fluid level will actually increase as normal
block and housing before bolt tightening. Infre- clutch wear occurs. For this reason, it is impor-
quently, misalignment may also be caused by housing tant to avoid overfilling, or removing fluid from
mounting surfaces that are not completely parallel. the reservoir. This will cause clutch release
Misalignment can be corrected with shims. problems.
If inspection or diagnosis indicates additional fluid
DIAGNOSTIC CHARTS may be needed, use Mopar௡ brake fluid, or an equiv-
The diagnosis charts describe common clutch prob- alent meeting standards SAE J1703 and DOT 3. Do
lems, causes and correction. Fault conditions are not use any other type of fluid.
listed at the top of each chart. Conditions, causes and
corrective action are outlined in the indicated col-
umns.

6. 6-6 CLUTCH XJ
SERVICE PROCEDURES (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT 1. Normal wear. Driver frequently 1. Replace clutch disc. Also replace
rides (slips) clutch. Results in rapid cover if spring is weak or pressure
war overheating. Insufficient clutch plate surface is damaged.
cover diaphragm spring tension.
CLUTCH DISC FACING 1. Leak at rear main seal or at 1. Replace leaking seals. Apply less
CONTAMINATED WITH OIL, transmission input shaft seal. grease to input shaft splines.
GREASE, OR CLUTCH FLUID Excessive amount of grease Replace clutch disc (do not clean
applied to input shaft splines. Road and reuse). Clean clutch cover
splash, water entering housing. and reuse only if cover is in good
Slave cylinder leaking. condition. Replace slave cylinder if
leaking.
CLUTCH IS RUNNING PARTIALLY 1. Release bearing sticking-binding. 1. Verify that bearing is actually
DISENGAGED Does not return to normal running binding, the replace bearing and
position. transmission front bearing retainer
if sleeve surface is damaged.
FLYWHEEL HEIGHT INCORRECT 1. Flywheel surface improperly 1. Replace flywheel.
machined. Too much stock
removed or surface is tapered.
WRONG DISC OR PRESSURE 1. Incorrect parts order or model 1. Replace with correct parts.
PLATE INSTALLED number. Compare old and new parts before
installation.
CLUTCH DISC, COVER AND/OR 1. Rough handling (impact) bent 1. Install new disc or cover as
DIAPHRAGM SPRING, SARPED, cover, spring, or disc. Incorrect bolt needed. Follow installation/
DISTORTED tightening sequence and method tightening instructions.
caused warped cover.
FACING ON FLYWHEEL SIDE OF 1. Flywheel surface scored and 1. Reduce scores and nicks by
DISC TORN, GOUGED, WORN nicked. sanding or surface grinding.
Replace flywheel if scores-nicks
are deeper than .002-.004 inch.
CLUTCH DISC FACING BURN 1. Frequent operation under high 1. Scuff sand flywheel. Replace
(CHARRED). FLYWHEEL AND loads or hard acceleration clutch cover and disc. Alert driver
COVER PRESSURE PLATE conditions. Driver frequently rides to problem cause.
SURFACES HEAVILY GLAZED (slips) clutch. Results in rapid wear
and overheating of disc and cover.

7. XJ CLUTCH 6-7
SERVICE PROCEDURES (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC WARPED 1. New disc not checked for axial 1. Replace disc. Be sure runout of
runout before installation. new disc is less than .5 mm (.020
in.).
CLUTCH DISC BINDS ON INPUT 1. Clutch disc hub splines damaged 1. Clean, smooth and lubricate disc
SHAFT SPLINES during installation. Input shaft and shaft splines. Replace disc
splines rough, damaged. and/or input shaft if splines are
Corrosion, rust formations on severely damaged.
splines of disc and input shaft.
CLUTCH DISC RUSTED TO 1. Occurs in vehicles stored, or not 1. Remove clutch cover and disc.
FLYWHEEL AND/OR PRESSURE driven for extended periods of Sand rusted surfaces clean with
PLATE time. Also occurs after steam 180 grit paper. Replace disc cover,
cleaning if vehicle is not used for and flywheel if corrosion is severe.
extended period.
CLUTCH DISC FACING STICKS TO 1. Vacuum may form in pockets over 1. Drill 1/16 inch diameter hole
FLYWHEEL rivet heads in clutch disc. Occurs through rivets and scuff sand disc
as clutch cools down after use. facing with 180 grit paper.
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED, LOOSE, 1. Bearing cocked during installation. 1. Lubricate and install new bearing.
OR ROLLERS ARE WORN Bearing defective. Bearing not Check and correct any
lubricated. Clutch misalignment. misalignment.
CLUTCH WILL NOT DISENGAGE 1. Low clutch fluid level. 1. Top off reservoir and check for
PROPERLY leaks.
2. Clutch cover loose. 2. Tighten bolts.
5. Clutch cover diaphragm spring 5. Replace cover.
bent or warped during transmission
installation.
6. Clutch disc installed backwards. 6. Remove and reinstall disc
correctly. Be sure disc side
marked “to flywheel” is actually
toward flywheel.
7. Release fork bent or fork pivot is 7. Replace fork and pivot if worn or
loose or damaged. damaged.
8. Clutch master or slave cylinder 8. Replace master and slave cylinder
fault. as assembly.

8. 6-8 CLUTCH XJ
SERVICE PROCEDURES (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING COVERED 1. Oil leak at rear main or input shaft 1. Correct leak and replace disc (do
WITH OIL, GREASE, OR CLUTCH seal. not clean and reuse the disc).
FLUID
2. Too much grease applied to 2. Apply lighter grease coating to
splines or disc and input shaft. splines and replace disc (do not
clean and reuse the disc).
CLUTCH DISC AND/OR COVER 1. Incorrect or substandard parts. 1. Replace disc and/or cover with
WARPED, OR DISC FACINGS correct parts.
EXHIBIT UNUSUAL WRONG TYPE
CLUTCH MASTER OR SLAVE 1. Master or slave cylinder 1. Replace both cylinders as
CYLINDER PLUNGER DRAGGING- components worn or corroded. assembly (and reservoir).
BINDING
NO FAULT FOUND WITH CLUTCH 1. Problem actually related to 1. Further diagnosis required. Check
COMPONENTS suspension or driveline component. engine/transmission mounts,
propeller shafts and U-joints, tires,
suspension attaching parts and
other driveline components as
needed.
2. Engine related problem. 2. Check EFI and ignition systems.
PARTIAL ENGAGEMENT OF 1. Clutch pressure plate position 1. Replace clutch cover and disc.
CLUTCH DISC (ONE SIDE setting incorrect or modified.
WORN-OPPOSITE SIDE GLAZED 2. Clutch cover, spring, or release 2. Replace clutch cover and disc.
AND LIGHTLY WORN) fingers bent, distorted (rough
handling, improper assembly).
3. Clutch disc damaged or distorted. 3. Replace disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.

9. XJ CLUTCH 6-9
SERVICE PROCEDURES (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
Clutch components damaged or worn 1. Incorrect or sub-standard clutch 1. Replace with parts of correct type
out prematurely. parts. and quality.
Pilot bearing damaged. 1. Bearing cocked during installation. 1. Replace bearing. Be sure it is
Bearing not lubricated prior to properly seated and lubricated
installation. Bearing defect. before installing clutch.
2. Clutch misalignment. 2. Check and correct misalignment
caused by excessive runout of
flywheel, disc, cover or clutch
housing. Replace input shaft if
bearing hub is damaged.
Loose components. 1. Attaching bolts loose at flywheel, 1. Tighten bolts to specified torque.
cover, or clutch housing. Replace any clutch bolts that are
damaged.
Components appear overheated. 1. Frequent high load, full throttle 1. Replace parts as needed. Alert
Hub of disc cracked or torsion operation. driver to condition causes.
damper springs are distorted or
broken.
Contact surface of release bearing 1. Clutch cover incorrect, or release 1. Replace clutch cover and bearing.
damaged. fingers are bent or distorted
causing damage.
2. Release bearing defect. 2. Replace bearing.
3. Release bearing misaligned. 3. Check and correct runout of clutch
components. Check front bearing
retainer sleeve surface. Replace if
damaged.
Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.
Clutch pedal squeak. 1. Pivot pin loose. Pedal bushings 1. Tighten pivot pin. Replace
worn out or cracked. bushings if worn or damaged.
Lubricate pin and bushings with
silicone base lubricator chassis
grease.

10. CYLINDER MASTER
CLUTCH MASTERRESERVOIR CAP
CLUTCH RESER-
VOIR
RESERVOIR
CYLINDER FLUIDFLUID LINEINDICA-
LEVELTOR RING
6 - 10 CLUTCH XJ
SERVICE PROCEDURES (Continued)
CLUTCH FLUID LEVEL FLYWHEEL
The clutch fluid reservoir, master cylinder, slave Inspect the flywheel whenever the clutch disc,
cylinder and fluid lines are pre-filled with fluid at cover and housing are removed for service. Check
the factory during assembly operations. condition of the flywheel face, hub, ring gear teeth,
The hydraulic system should not require additional and flywheel bolts.
fluid under normal circumstances. In fact, the reser- Minor scratches, burrs, or glazing on the flywheel
voir fluid level will actually increase as normal face can be reduced with 180 grit emery cloth. How-
clutch wear occurs. For this reason, it is impor- ever, the flywheel should be replaced if the disc con-
tant to avoid overfilling, or removing fluid from tact surface is severely scored, heat checked, cracked,
the reservoir. or obviously worn.
If inspection or diagnosis indicates additional fluid Flywheel machining is not recommended. The fly-
may be needed, use Mopar௡ brake fluid, or an equiv- wheel surface is manufactured with a unique contour
alent meeting standards SAE J1703 and DOT 3. Do that would be negated by machining. However,
not use any other type of fluid. cleanup of minor flywheel scoring can be performed
Clutch fluid level is checked at the master cylinder by hand with 180 grit emery, or with surface grind-
reservoir (Fig. 1). An indicator ring is provided either ing equipment. Replace the flywheel if scoring is
on the side, or interior rim of the reservoir (Fig. 2). deeper than 0.0762 mm (0.003 in.).
Be sure to wipe the reservoir and cover clean Heavy stock removal by grinding is not recom-
before removing the cover. This will avoid having dirt mended. Excessive stock removal can result in fly-
or foreign material fall into the reservoir during a wheel cracking or warpage after installation. It can
fluid level check. 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.
Fig. 1 Clutch Master Cylinder Reservoir And Cap 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 resistent gloves when han-
dling a heated ring gear.
Fig. 2 Reservoir Fluid Level Indicator Ring

11. PUNCH MARKS
CLUTCH COVER
FLYWHEEL
XJ CLUTCH 6 - 11
SERVICE PROCEDURES (Continued)
(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 Fig. 3 Typical Method Of Marking Clutch Cover
gear teeth resulting in rapid wear and damage after Position
installation. (4) Remove cover bolts and remove cover and disc
(Fig. 4).
(5) The heated gear must be installed evenly to
avoid misalignment or distortion. A shop press and INSTALLATION
suitable press plates should be used to install the (1) Lightly scuff sand flywheel face with 180 grit
gear if at all possible. emery cloth. Then clean surface with a wax and
(6) Be sure to wear eye and hand protection. Heat grease remover.
resistent gloves and safety goggles are needed for (2) Lubricate pilot bearing with Mopar௡ high tem-
personal safety. Also use metal tongs, vise grips, or perature bearing grease.
similar tools to position the gear as necessary for (3) Check new clutch for runout and free operation
installation. on input shaft splines.
(7) Allow the flywheel and ring gear to cool down (4) Position clutch disc on flywheel. Be sure side of
before installation. Set the assembly on a workbench disc marked flywheel side is positioned against fly-
and let it cool in normal shop air. wheel (Fig. 4). If disc is not marked, be sure flat side
of disc hub is toward flywheel.
CAUTION: Do not use water, or compressed air to
(5) Inspect condition of pressure plate surface of
cool the flywheel. The rapid cooling produced by
clutch cover (Fig. 4). Replace cover if this surface is
water or compressed air can distort, or crack the
worn, heat checked, cracked, or scored.
gear and flywheel.
(6) Insert clutch alignment tool in clutch disc (Fig.
5).
(7) Insert alignment tool in pilot bearing and posi-
REMOVAL AND INSTALLATION tion disc on flywheel. Be sure disc hub is positioned
correctly. Side of hub marked Flywheel Side should
CLUTCH COVER AND DISC face flywheel (Fig. 4). If disc is not marked, place flat
side of disc against flywheel.
REMOVAL (8) Position clutch cover over disc and on flywheel
(1) Remove transmission. Refer to Group 21, (Fig. 5).
Transmission and Transfer Case, for proper proce- (9) Install clutch cover bolts finger tight.
dures. (10) Tighten cover bolts evenly and in rotation a
(2) If original clutch cover will be reinstalled, mark few threads at a time. Cover bolts must be tightened
position of cover on flywheel for assembly reference evenly and to specified torque to avoid distorting
(Fig. 3). Use paint or a scriber for this purpose. cover. Tightening torques are 31 N·m (23 ft. lbs.) on
(3) Loosen cover bolts evenly and in rotation to 2.5L engines and 54 N·m (40 ft. lbs.) on 4.0L engines.
relieve spring tension equally. This is necessary to
avoid warping cover.

12. DISC STAMPED ON THIS SIDE”
“FLYWHEEL SURFACE
INSPECT THIS
FACE
SUR- CLUTCH COVER ENGINE (4.0L) BRACKET
CLUTCH
HOUSING FLYWHEEL TRANSFER CASE TUBE
VENT CLUTCH DISC ALIGNMENT
CLUTCH COVER AND TOOL
TORQUE DISC
ITEM
6 - 12 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 4 Clutch Disc And Pressure Plate Inspection Fig. 5 Typical Method Of Aligning Clutch Disc
(11) Apply light coat of Mopar௡ high temperature (3) Remove release bearing, release fork, and fork
bearing grease to pilot bearing hub and splines of boot from input shaft and clutch housing.
transmission input shaft. Do not over lubricate shaft (4) Remove bolts attaching clutch housing to trans-
splines. This will result in grease contamination of mission (Fig. 8).
disc.
(12) Install transmission (Fig. 6) and (Fig. 7). INSTALLATION
Refer to Group 21, Transmission and Transfer Case, (1) Clean mounting surfaces of transmission and
for proper procedures. clutch housing. Use a wire brush if necessary fol-
lowed by a wax and grease remover, or similar sol-
CLUTCH HOUSING REPLACEMENT—AX15 vent. Also clean engine block surface as well.
(2) Position clutch housing on transmission and
REMOVAL install housing attaching bolts. Tighten bolts to 38
(1) Raise vehicle and support vehicle. N·m (28 ft. lbs.) torque.
(2) Remove transmission and clutch housing as (3) Install release fork pivot ball stud to housing, if
assembly. Refer to Group 21, Transmission and necessary.
Transfer Case, for proper procedures.
Fig. 6 Manual Transmission Mounting—4.0L

13. BOLTS (38 ft. lbs.)
TRANSMISSION
HOUSING N·m/28
—TO- CLUTCH
HOUSINGFWD ENGINE (2.5L)
TRANSMISSION
COVER BRACKET
PIVOT 23 N·m LBS.) SPRING SLEEVE
RELEASE BEARING WASHER
CLUTCH
IN. (200
HOUSING CONED AND RELEASE CLUTCH HOUSING
FORK
TORQUE
ITEM
XJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
Fig. 7 Manual Transmission Mounting—2.5L
bearing retainer slide surface with light coat of same
grease.
(5) Install release fork, bearing, and boot in hous-
ing. Be sure release fork boot is properly seated in
housing.
(6) Install transmission. Refer to Group 21, Trans-
mission and Transfer Case, for proper procedures.
RELEASE BEARING
REMOVAL
(1) Remove transmission. Refer to Group 21,
Transmission and Transfer Case, for proper proce-
dures.
(2) Disconnect release bearing from fork and
remove bearing (Fig. 9).
Fig. 8 Clutch Housing Attachment
(4) Lubricate release bearing bore, release fork
contact surfaces, and release fork pivot stud with
Mopar௡ high temperature bearing grease. Also lubri-
cate transmission input shaft splines, pilot hub and Fig. 9 Release Bearing And Release Fork Mounting

14. ING BEARINGPILOT TO AVOID
KEEP INSTALLATION BEARING
MUST
BEARING DAMAGE
ALIGNMENTFACE
STRAIGHT SEAL
TRANSMISSION
DUR-
TOOL
6 - 14 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Inspect release bearing slide surface of trans-
mission front bearing retainer. Replace retainer if
slide surface is scored, worn or cracked.
(2) Inspect release fork and fork pivot (Fig. 9). Be
sure pivot is secure and in good condition. Be sure
fork is not distorted or worn. Replace release fork
retainer spring if bent or damaged in any way.
(3) Lightly lubricate pilot bearing, input shaft
splines, bearing retainer slide surface, fork pivot and
release fork pivot surface with Mopar௡ high temper-
ature bearing grease.
(4) Install release fork and bearing. Be sure fork
and bearing are properly secured.
(5) Install transmission. Refer to Group 21, Trans-
mission and Transfer Case, for proper procedures.
PILOT BEARING
REMOVAL
(1) Remove transmission. Refer to Group 21,
Transmission and Transfer Case, for proper proce-
dures. Fig. 10 Typical Method Of Installing Pilot Bearing
(2) Remove clutch cover and disc.
REMOVAL
(3) Use a suitable blind hole puller to remove pilot
(1) Raise vehicle.
bearing.
(2) Remove fasteners attaching slave cylinder to
INSTALLATION clutch housing.
(1) Clean bearing bore with solvent and wipe dry (3) Remove slave cylinder from clutch housing
with shop towel. (Fig. 11).
(2) Lubricate new pilot bearing with Mopar௡ high (4) Disengage clutch fluid line from body clips.
temperature grease. (5) Lower vehicle.
(3) Position and start new bearing in bearing bore (6) Verify that cap on clutch master cylinder reser-
by hand. Note that pilot bearing has seal at one end. voir is tight. This is necessary to avoid undue spill-
Install bearing so seal is facing outward toward age during removal.
transmission. (7) Remove clutch master cylinder attaching nuts.
(4) Seat pilot bearing with clutch alignment tool Note that both nuts are accessible from under instru-
(Fig. 10). Keep bearing straight during installation. ment panel (Fig. 12) and (Fig. 13).
Do not allow bearing to become cocked. Tap bearing (8) Remove clutch master cylinder push rod from
into place until flush with edge of bearing bore. Do pedal.
not recess bearing. (9) Disconnect clutch pedal position switch wires.
(5) Install transmission. Refer to Group 21, Trans- (10) If pedal pin is equipped with bushing, inspect
mission and Transfer Case, for proper procedures. condition of bushing and replace it if worn or dam-
aged.
CLUTCH HYDRAULIC LINKAGE (11) Remove clutch hydraulic linkage through
The clutch master cylinder, slave cylinder and con- engine compartment.
necting line are serviced as an assembly only. The
INSTALLATION
linkage components cannot be overhauled or serviced
(1) Be sure reservoir cover on clutch master cylin-
separately. The cylinders and connecting line are
der is tight to avoid spills.
sealed units. Also note that removal/installation pro-
(2) Position clutch linkage components in vehicle.
cedures for right and left hand drive models are basi-
Work connecting line and slave cylinder downward
cally the same. Only master cylinder location is
past engine and adjacent to clutch housing.
different.
(3) Position clutch master cylinder on dash panel.
(4) Attach clutch master cylinder push rod to
clutch pedal pin.

15. CLUTCHFWD CYLINDER FLUID LINE PANEL
MASTER CYLINDER DASH SLAVE CYLIN- HOUSING
CLUTCH
DER PUSH ROD
STUDS (2)
XJ CLUTCH 6 - 15
REMOVAL AND INSTALLATION (Continued)
Fig. 11 Slave Cylinder Attachment
Fig. 13 Clutch Master Cylinder Location—Right
Hand Drive Models
(11) Connect clutch pedal position switch wires.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bolts, clutch cover 2.5 L . . . . . . . 31 N·m (23 ft. lbs)
Bolts, clutch cover 4.0 L . . . . . . . 52 N·m (38 ft. lbs)
Bolt/Nut, clutch cyl. mount . . . . 23 N·m (200 in. lbs)
Fig. 12 Clutch Master Cylinder And Push Rod Bolt, clutch housing M12 . . . . . . . 75 N·m (55 ft. lbs)
Attachment—Left Hand Drive Models Bolt, clutch housing 3/8 . . . . . . . . 37 N·m (27 ft. lbs)
Bolt, clutch housing 7/16 . . . . . . . 58 N·m (43 ft. lbs)
Bolt, clutch housing/trans. . . . . . . 38 N·m (28 ft. lbs)
Bolt, dust shield M8 . . . . . . . . . . . 8 N·m (72 in. lbs)
(5) Install and tighten clutch master cylinder Bolt, dust shield lower . . . . . . . . . 50 N·m (37 ft. lbs)
attaching nuts to 23-34 N·m (200-300 in. lbs.) torque. Bolt, X-member/frame . . . . . . . . . 41 N·m (30 ft. lbs)
(6) Raise vehicle. Bolt, X-member/rear support . . . 45 N·m (33 ft. lbs.)
(7) Insert slave cylinder push rod through clutch Bolts, flywheel 4.0 L . . . . . . . . 142 N·m (105 ft. lbs)
housing opening and into release lever. Be sure cap Bolts, flywheel 2.5 L . . 68 N·m (50 ft. lbs) +1/4 turn
on end of rod is securely engaged in lever. Check this Bolt, starter motor . . . . . . . . . . . . 45 N·m (33 ft. lbs)
before installing cylinder attaching nuts.
Bolts, U-joints . . . . . . . . . . . . . 19 N·m (170 in. lbs.)
(8) Install and tighten slave cylinder attaching
nuts to 23-34 N·m (200-300 in. lbs.) torque.
(9) Secure clutch fluid line in body clips.
(10) Lower vehicle.

17. XJ CLUTCH 6-1
CLUTCH
CONTENTS
page page
GENERAL INFORMATION FLYWHEEL . . . . ........................ 3
CLUTCH COMPONENTS . . . . . ............. 1 PILOT BEARING ........................ 1
CLUTCH HYDRAULIC SYSTEM ............. 1 SPECIFICATIONS
REMOVAL AND INSTALLATION SPECIFICATIONS ....................... 5
CLUTCH COVER AND DISC . . ............. 1 SPECIAL TOOLS
FLYWHEEL RING GEAR . . . . . ............. 4 SPECIAL TOOLS ........................ 5
GENERAL INFORMATION a star pattern to relieve spring tension equally. This
is necessary to avoid warping the cover.
CLUTCH COMPONENTS (4) Remove clutch cover bolts and remove cover
The clutch mechanism consists of a single, dry-type and disc (Fig. 1)
clutch disc and a diaphragm style clutch cover. A
hydraulic linkage is used to operate the clutch disc INSTALLATION
and cover. The clutch components are very similar to (1) Lightly scuff sand flywheel face with 180 grit
those used in gas engine models. emery cloth. Then clean surface with brake or carbu-
A pilot bearing is used to support the transmission retor cleaner.
input shaft. The bearing is seated in a separate, (2) Lightly lubricate pilot bearing with Mopar௡
removable housing bolted to the flywheel hub. high temperature bearing grease.
(3) Check free operation of clutch disc by sliding
CLUTCH HYDRAULIC SYSTEM disc onto transmission output shaft splines. Disc
The clutch hydraulic system should not require should slide onto splines freely without binding.
additional fluid under normal circumstances. (4) Position clutch disc on flywheel. Be sure side of
disc marked “flywheel side” is positioned against fly-
NOTE: The reservoir fluid level will actually wheel (Fig. 2). If disc is not marked, be sure flat side
increase as normal clutch wear occurs. For this rea- of disc hub is placed toward the flywheel.
son, it is important to avoid over filling, or remov- (5) Insert clutch alignment tool (Fig. 3) in clutch
ing fluid from the reservoir. disc and pilot bearing.
(6) Position clutch cover over disc and on flywheel.
If inspection indicates additional fluid is needed, (7) Install clutch cover bolts finger tight.
add fluid from a sealed container only. Use Mopar௡ (8) Starting with the bolts marked “P” on the cover
brake fluid, or an equivalent meeting standards SAE first, tighten clutch cover bolts in a star pattern to 50
J1703 and DOT 3. Do not use any other type of fluid. N·m torque.
(9) Apply light coat of Mopar௡ high temperature
bearing grease to pilot bearing and splines of trans-
REMOVAL AND INSTALLATION mission input shaft.
CLUTCH COVER AND DISC CAUTION: Do not over-lubricate as this will result
in grease contamination of the disc.
REMOVAL
(1) Remove transmission and transfer case, if (10) Install transmission.
equipped. (Refer to Group 21, Transmission and
Transfer Case) PILOT BEARING
(2) If original clutch cover will be reinstalled, mark
position of cover on flywheel for assembly reference. REMOVAL
Use paint or scribe for this purpose. (1) Remove transmission. (Refer to Group 21,
(3) If clutch cover is to be replaced, cover bolts can Transmission and Transfer Case)
be removed in any sequence. However, if original (2) Remove clutch cover and disc.
cover will be reinstalled, loosen cover bolts evenly in (3) Remove the four bolts that attach the pilot
bearing retainer to the flywheel (Fig. 4).

18. 6-2 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 1 Clutch Components (VM Diesel)
Fig. 3 Clutch Disc Alignment—Typical
(6) Remove the pilot bearing with a suitable sized
socket and extension (Fig. 5). Use mallet to tap bear-
ing out of retainer.
Fig. 2 Clutch Disc Position
(4) Remove the pilot bearing retainer.
(5) Support the bearing retainer on two wood
blocks.

19. XJ CLUTCH 6-3
REMOVAL AND INSTALLATION (Continued)
Fig. 4 Pilot Bearing Retainer Bolt Removal/ Fig. 7 Pilot Bearing Seated In Retainer
Installation the letters on the bearing will both be facing out
(toward the clutch) after installation.
(1) Install new pilot bearing with hammer and tool
handle C-4171. (Fig. 6). Seat bearing flush with
lower edge of chamfer in retainer bore (Fig. 7). Repo-
sition bearing if necessary.
(2) Install bearing retainer and tighten bolts.
(3) Lubricate pilot bearing with Mopar௡ high tem-
perature wheel bearing grease.
(4) Lightly scuff sand flywheel surface with 180
grit emery cloth. Clean the surface with Mopar௡
brake or carburetor cleaner.
(5) Install clutch disc and cover as described in
this section
(6) Install transmission and Transfer Case.
Fig. 5 Pilot Bearing Removal
FLYWHEEL
REMOVAL
(1) Remove transmission and clutch housing.
(Refer to Group 21, Transmission and Transfer Case)
(2) Remove clutch cover and disc as described in
this section.
(3) Remove bolts that attach pilot bearing retainer
to flywheel.
(4) Remove pilot bearing and retainer.
(5) Remove flywheel bolts.
(6) Grasp flywheel firmly and work it off the
crankshaft flange (side to side or up and down). Be
sure to maintain a firm grip as the flywheel is heavy.
(7) Remove the o-ring from the crankshaft flange,
or the mounting shoulder of the flywheel (Fig. 9).
Fig. 6 Pilot Bearing Installation (8) Clean the flywheel in solvent.
INSTALLATION INSPECTION
Examine flywheel mounting surfaces, clutch con-
CAUTION: The bearing can be installed incorrectly
tact surface, and ring gear. Check condition of fly-
if care is not exercised. Check bearing position
wheel hub and attaching bolts. Replace flywheel if
before installing it Make sure the bearing seal and

20. 6-4 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)
hub exhibits cracks in the area of attaching bolt
holes. Replace ring gear if the teeth are damaged.
Resurface the flywheel if the clutch contact surface is
scored or rough (refer to flywheel finishing and ring
gear replacement information in this section.
Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm. Measure
flywheel face runout with a dial indicator (Fig. 8).
Mount the indicator on a stud installed in the engine
block or in one of the flywheel attaching bolt holes.
Face runout can be corrected by resurfacing if neces-
sary. Surface grinding equipment is recommended for
this purpose. Stock removal should not exceed 0.25
mm.
Fig. 10 Flywheel Bolt Tightening Pattern
(2) Install new o-ring in the flywheel mounting
flange (Fig. 9). Use grease to hold the ring in place.
(3) Mount flywheel to crankshaft and align the
bolt holes.
(4) Install and tighten new flywheel bolts as fol-
lows:
(a) Lubricate bolt threads with engine oil.
(b) Install and tighten bolts to initial torque of
20 N·m. Tighten bolts diagonally in pairs (Fig. 10).
(c) Tighten each bolt and additional 60° turn.
Fig. 8 Checking Flywheel Runout Continue tightening bolts in small increments to
INSTALLATION final torque of 130 N·m.
(5) Install clutch disc and cover (refer to procedure
in this section).
(6) Install transmission and transfer case.
FLYWHEEL RING GEAR
REMOVAL
(1) Remove the transmission and transfer case.
(Refer to Group 21, Transmission and Transfer Case)
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
(5) Mark position of the old gear for alignment ref-
erence. Use a carbide tipped scribe to mark gear loca-
tion on flywheel.
(6) Wear protective goggles or approved safety
glasses.
(7) Remove the old gear by cutting most of the way
through it at one point. Use an abrasive cut off wheel
for this purpose. Break the ring gear at cut with a
hammer and a cold chisel or punch
(8) Ring gear is shrink fit on flywheel. This means
the gear must be expanded by heating in order to
Fig. 9 Flywheel Mounting (VM Diesel) install it.
(1) Clean crankshaft flange before mounting the
flywheel. Dirt or grease on flange surface may cock
flywheel causing run-out.

21. XJ CLUTCH 6-5
REMOVAL AND INSTALLATION (Continued)
NOTE: The method of heating and expanding the SPECIFICATIONS
new ring gear is extremely important. Every surface
of the gear must be heated at the same time to pro- SPECIFICATIONS
duce uniform expansion. An oven or similar
enclosed heating device must be used. Temperature DESCRIPTION TORQUE
required for uniform expansion is approximately Clutch Cover to Flywheel
350°-375°. Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N·m
Clutch Housing to Transmission
CAUTION: Do not use an oxy/acetylene torch to Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m
remove the old gear, or to heat and expand a new Flywheel to Crankshaft
gear. The high temperature of the torch flame can Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 N·m
cause localized heating that will damage the fly- Pilot Bearing Retainer to Flywheel/Crankshaft
wheel. In addition, using the torch to heat a replace- Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m
ment gear will cause uneven heating and Clutch Housing to Engine
expansion. The torch flame can also anneal the Top (2) Bolts . . . . . . . . . . . . . . . . . . . . . . . 37 N·m
gear teeth resulting in rapid wear and damage after Middle (2) Bolts . . . . . . . . . . . . . . . . . . . . . 58 N·m
installation. Bottom (2) Bolts . . . . . . . . . . . . . . . . . . . . 75 N·m
INSTALLATION
SPECIAL TOOLS
(1) Position and install the heated ring gear on the
flywheel:
SPECIAL TOOLS
(a) Wear heat resistant gloves to handle the hot
ring gear.
(b) Align the ring gear on the flywheel evenly.
(c) Use hammer and brass drift to tap ring gear
onto the flywheel.
(d) Seat gear on flywheel
(2) Allow the ring gear to cool down before instal-
lation on the engine. Place flywheel on work bench
and let it cool in normal shop air.
(3) Install flywheel and torque bolts to 130 N·m.
(4) Install clutch cover and disc. Refer to procedure
in this section.
(5) Install transmission and transfer case.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by Universal Handle—C-4171
water or compressed air will distort or crack the
new gear.