1. ZJ CLUTCH 6-1
CLUTCH
CONTENTS
page page
CLUTCH DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION .................. 1
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INDEX
page page
Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 1 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Component Lubrication . . . . . . . . . . . . . . . . . 2 Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . 1
Clutch Linkage Fluid . . . . . . . . . . . . . . . . . . . . . . . . 1 Hydraulic Linkage Components . . . . . . . . . . . . . . . . 1
CLUTCH COMPONENTS der is mounted on the driver side of the dash panel
The clutch mechanism in Grand Cherokee models next to the brake master cylinder.
consists of a single dry disc, and a diaphragm style The linkage components are not serviced sepa-
clutch cover. A hydraulic linkage is used to operate rately. The linkage is only serviced as a complete as-
the clutch release lever and bearing. sembly.
The transmission input shaft is supported in the
crankshaft flange by a pilot bearing. A sleeve type re- CLUTCH LINKAGE FLUID
lease bearing is used to engage and disengage the The clutch fluid reservoir, master cylinder, slave
clutch cover pressure plate. The bearing rides on the cylinder and fluid lines are pre-filled with fluid at
transmission front bearing retainer. the factory during assembly operations.
The release bearing is operated by a fork in the The hydraulic system should not require additional
clutch housing. The fork pivots on a ball stud and is fluid under normal circumstances. In fact, the reser-
operated by the hydraulic slave cylinder piston. The voir fluid level will actually increase as normal
slave cylinder is mounted in the clutch housing and clutch wear occurs. For this reason, it is impor-
is operated by the clutch master cylinder. The clutch tant to avoid overfilling, or removing fluid from
master cylinder is mounted on the dash panel and the reservoir.
the cylinder piston is connected to the clutch pedal. If inspection indicates additional fluid is needed,
The clutch disc has cushion springs in the disc hub use Mopar brake fluid, or an equivalent meeting
and the disc facing is riveted to the hub. The facing standards SAE J1703 and DOT 3. Do not use any
is made from a non-asbestos material. other type of fluid and only use fluid from a sealed
The clutch cover pressure plate is a diaphragm container.
type with a one-piece spring and multiple release fin-
gers. The pressure plate release fingers are preset CLUTCH PEDAL POSITION SWITCH
during manufacture and are not adjustable. A clutch pedal position switch has been added to
the starter circuit. The switch is in circuit with the
HYDRAULIC LINKAGE COMPONENTS starter solenoid and requires that the clutch pedal be
The hydraulic linkage consists of a remote reser- fully depressed in order to start the engine. Switch
voir, master cylinder, slave cylinder and interconnect- circuitry and operation is described in section 8W of
ing fluid lines. Group 8.
The clutch master cylinder piston is connected to The switch is located on the clutch master cylinder
the clutch pedal. The slave cylinder piston is con- push rod and is not serviced separately. It is serviced
nected to the clutch release lever. The master cylin- as part of the clutch master cylinder assembly.
2. 6-2 CLUTCH ZJ
CLUTCH COMPONENT LUBRICATION ponents. The pressure plate clamps the clutch disc
Proper clutch component lubrication is important against the flywheel. Clamping force on the pressure
to satisfactory operation. Using the correct lubricant plate, comes from the diaphragm spring.
and not overlubricating are equally important. Apply The clutch disc has a splined hub for installation
recommended lubricant sparingly to avoid disc and on the transmission input shaft splines. The splined
pressure plate contamination. hub provides the connection to the transmission.
Clutch and transmission components requiring lu- The clutch linkage uses hydraulic pressure to oper-
brication are: ate the clutch mechanism. The clutch master cylin-
• pilot bearing der is connected to the clutch pedal and the slave
• release lever pivot ball stud cylinder is connected to the release lever.
• release lever contact surfaces Pressing the clutch pedal develops fluid pressure in
• release bearing bore the clutch master cylinder. This pressure is transmit-
• clutch disc hub splines ted to the slave cylinder through the connecting line.
• clutch pedal pivot shaft bore The slave cylinder piston then operates the clutch re-
• clutch pedal bushings lease lever.
• transmission input shaft splines
The clutch release bearing is mounted on the
• transmission input shaft pilot hub
transmission front bearing retainer. The bearing is
• transmission front bearing retainer slide surface
attached to the release lever which moves the bear-
Never apply grease to any part of the clutch
ing in and out of contact with the diaphragm spring
cover, or disc.
fingers. The release lever is operated by the slave
RECOMMENDED LUBRICANTS cylinder piston rod.
Use Mopar multi-purpose grease for the clutch In operation, slave cylinder force exerted through
pedal bushings and pivot shaft. Use Mopar high tem- the cylinder piston, causes the release lever to pivot
perature grease (or equivalent) for all other lubrica- toward the clutch. This action moves the release
tion requirements. Apply recommended amounts and bearing into contact with the diaphragm spring fin-
do not overlubricate. gers. The release bearing pushes the spring fingers
inward against the fulcrums to unload spring force
CLUTCH OPERATION on the pressure plate. At this point, clamping force
Leverage, clamping force, and friction are the on the disc is released allowing the disc to disengage
clutch operating principles. The disc serves as the and freewheel.
friction element and the cover diaphragm spring act- The process of clutch re-engagement, is simply the
ing on the pressure plate provide the clamping force. reverse of what occurs during disengagement. Releas-
The pedal, hydraulic linkage, release lever and bear- ing pedal pressure removes linkage pressure. The re-
ing provide the leverage. lease bearing moves away from the diaphragm spring
The clutch cover assembly consists of the cover, which again applies clamping force on the disc
pressure plate, diaphragm spring and fulcrum com- through the pressure plate.
3. ZJ CLUTCH DIAGNOSIS 6-3
CLUTCH DIAGNOSIS
INDEX
page page
Clutch Contamination . . . . . . .. . . . . . . . . . . . . . . . 3 Flywheel Runout . . . . . . . . . . . . . . . .... . . . . . . . . 3
Clutch Cover and Disc Runout . . . . . . . . . . . . . . . . 3 General Diagnosis Information . . . . .... . . . . . . . . 3
Clutch Housing Misalignment .. . . . . . . . . . . . . . . . 4 Inspection and Diagnosis Charts . . . .... . . . . . . . . 4
Clutch Misalignment . . . . . . . .. . . . . . . . . . . . . . . . 3 Installation Methods and Parts Usage ... . . . . . . . . 4
GENERAL DIAGNOSIS INFORMATION Misalignment caused by excessive runout or warpage
Unless the cause of a clutch problem is obvious, ac- of any clutch component will cause grab, chatter and
curate problem diagnosis will usually require a road improper clutch release.
test to confirm a problem. Component inspection will
then be required to determine the actual problem FLYWHEEL RUNOUT
cause. Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
During a road test, drive the vehicle at normal
mm (0.003 in.). Measure runout at the outer edge of
speeds. Shift the transmission through all gear
the flywheel face with a dial indicator. Mount the in-
ranges and observe clutch action. If chatter, grab,
dicator on a stud installed in place of one of the fly-
slip, or improper release is experienced, remove and
wheel bolts.
inspect the clutch components. However, if the prob- Common causes of runout are:
lem is noise or hard shifting, further diagnosis may • heat warpage
be needed as the transmission or another driveline • improper machining
component may be at fault. Careful observation dur- • incorrect bolt tightening
ing the test will help narrow the problem area. • improper seating on crankshaft flange shoulder
• foreign material on crankshaft flange
CLUTCH CONTAMINATION Flywheel machining is not recommended. The fly-
Fluid contamination is a frequent cause of clutch wheel clutch surface is machined to a unique contour
malfunction. Oil, water, or clutch fluid on the clutch and further machining will negate this feature.
contact surfaces will cause chatter, slip, or grab. Minor flywheel scoring can be smoothed by hand
During inspection, note if any components are con- with 180 grit emery, or with surface grinding equip-
taminated with oil, hydraulic fluid, or water/road ment. Remove only enough material to reduce scor-
splash. ing (approximately 0.001 - 0.003 in.). Heavy stock
Oil contamination indicates a leak at either the removal is not recommended. Replace the flywheel
rear main seal or transmission input shaft. Oil leak- if scoring is severe and deeper than 0.076 mm (0.003
age produces a residue of oil on the housing interior in.). Excessive stock removal can result in flywheel
and on the clutch cover and flywheel. Heat buildup cracking or warpage after installation; it can also
caused by slippage between the cover, disc and fly- weaken the flywheel and interfere with proper clutch
wheel, can sometimes bake the oil residue onto the release.
components. The glaze-like residue ranges in color Clean the crankshaft flange before mounting the
from amber to black. flywheel. Dirt and grease on the flange surface may
Road splash contamination means dirt/water is en- cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
tering the clutch housing due to loose bolts, housing
bolts with Mopar Lock And Seal. Tighten flywheel
cracks, or through hydraulic line openings. Driving
bolts to specified torque only. Overtightening can dis-
through deep water puddles can force water/road
tort the flywheel hub causing runout.
splash into the housing through such openings.
Clutch fluid leaks are from loose or damaged slave CLUTCH COVER AND DISC RUNOUT
cylinder fluid lines and connecting fittings. However, Check the clutch disc before installation. Axial
clutch fluid leaks will usually be noted and corrected (face) runout of a new disc should not exceed 0.50
before severe contamination occurs. mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain an-
CLUTCH MISALIGNMENT other disc if runout is excessive.
Clutch components must be in proper alignment Check condition of the clutch before installation. A
with the crankshaft and transmission input shaft. warped cover or diaphragm spring will cause grab
4. 6-4 CLUTCH DIAGNOSIS ZJ
and incomplete release or engagement. Be careful Improper clutch cover bolt tightening can distort
when handling the cover and disc. Impact can distort the cover. The usual result is clutch grab, chatter
the cover, diaphragm spring, release fingers and the and rapid wear. Tighten the cover bolts as described
hub of the clutch disc. in Clutch Service section.
Use an alignment tool when positioning the disc on An improperly seated flywheel and/or clutch hous-
the flywheel. The tool prevents accidental misalign- ing are additional causes of clutch failure. Improper
ment which could result in cover distortion and disc seating will produce misalignment and additional
damage. clutch problems.
A frequent cause of clutch cover distortion (and The use of non-standard or low quality parts will
consequent misalignment) is improper bolt tighten- also lead to problems and wear. Use recommended
ing. To avoid warping the cover, the bolts must tight- factory quality parts to avoid comebacks.
ened alternately (diagonal pattern) and evenly (2-3
A cocked pilot bearing is another cause of clutch
threads at a time) to specified torque.
noise, drag, hard shifting, and rapid bearing wear.
CLUTCH HOUSING MISALIGNMENT Always use an alignment tool to install a new bear-
ing. This practice avoids bearing misalignment dur-
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment ing installation.
between the crankshaft and transmission input
shaft. Misalignment can cause clutch noise, hard INSPECTION AND DIAGNOSIS CHARTS
shifting, incomplete release and chatter. It can also The clutch inspection chart (Fig. 1) outlines items
result in premature wear of the pilot bearing, cover to be checked before and during clutch installation.
release fingers and clutch disc. In severe cases, mis- Use the chart as a check list to help avoid overlook-
alignment can also cause premature wear of the ing potential problem sources during service opera-
transmission input shaft and front bearing. tions.
Housing misalignment is generally caused by incor- The diagnosis charts describe common clutch prob-
rect seating on the engine or transmission, loose lems, causes and correction. Fault conditions are
housing bolts, missing alignment dowels, or housing listed at the top of each chart. Conditions, causes and
damage. Infrequently, misalignment may also be corrective action are outlined in the indicated col-
caused by housing mounting surfaces that are not umns. Use the charts as a guide when diagnosing
completely parallel. Misalignment can be corrected faulty clutch operation.
with shims.
INSTALLATION METHODS AND PARTS USAGE
Distortion of clutch components during installation
and the use of non-standard components are addi-
tional causes of clutch malfunction.
10. 6 - 10 CLUTCH SERVICE ZJ
CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation . . . . . . . . . . . . . 10 Clutch Pedal Installation . . . . ................ 13
Clutch Cover and Disc Removal . . . . . . . . . . . . . . 10 Clutch Pedal Removal . . . . . . ................ 13
Clutch Housing Installation . . . . . . . . . . . . . . . . . . 11 Flywheel Service . . . . . . . . . . ................ 14
Clutch Housing Removal . . . . . . . . . . . . . . . . . . . . 11 Pilot Bearing Replacement . . ................ 12
Clutch Hydraulic Linkage Installation . . . . . . . . . . . 12 Release Bearing Replacement ................ 11
Clutch Hydraulic Linkage Removal . . . . . . . . . . . . . 12 Starter Ring Gear Service . . . ................ 14
CLUTCH COVER AND DISC REMOVAL
(1) Raise vehicle.
(2) Remove transmission and clutch housing as as-
sembly (Fig. 2). Refer to Group 21 for procedures.
(3) If clutch cover will be reused, mark position of
cover on flywheel with scriber, chalk, or center punch
(Fig. 2).
(4) Loosen clutch cover bolts evenly and in rotation
to relieve spring tension. Loosen bolts a few threads
at a time only to avoid warping cover. This is espe-
cially important if cover will be reused.
(5) Remove cover bolts and remove cover and disc.
CLUTCH COVER AND DISC INSTALLATION
(1) Reduce minor scratches or surface glazing on
flywheel face with 120/180 grit emery cloth. Clean
flywheel surface with Mopar brake cleaner or wax Fig. 2 Clutch Disc Position
and grease remover afterward.
(2) Check runout and free operation of new clutch
disc.
(a) Install disc on transmission input shaft
splines. Be sure disc slides freely on splines. Leave
disc on splines for runout check.
(b) Measure disc runout with dial indicator. Posi-
tion indicator plunger about 6 mm (1/4 in.) from
outer edge of disc facing.
(c) Rotate input shaft and note indicator reading.
Disc runout should not exceed 0.5 mm (0.020 inch).
Obtain another disc if runout exceeds this limit.
(3) Lubricate crankshaft pilot bearing with Mopar
high temperature grease, or equivalent.
(4) Insert clutch alignment tool in disc and position
disc on flywheel.
(5) Verify that disc hub is positioned correctly. Side Fig. 3 Clutch Disc Alignment
of hub marked ‘‘Flywheel Side’’ should face flywheel
(Fig. 2). CAUTION: Tighten the clutch cover bolts evenly in a
(6) Insert alignment tool or spare input shaft in pi- star pattern to avoid distorting the cover.
lot bushing and position disc on flywheel (Fig. 3).
(10) Apply light coating of Mopar high temp grease
(7) Position clutch cover over disc and on flywheel.
Verify that disc and cover are aligned before proceed- to input shaft splines and to release bearing slide
ing. surface of front bearing retainer. Do not overlubri-
(8) Install and tighten clutch cover bolts until snug cate shaft splines. This could result in grease
but not to specified torque. contamination of disc.
(9) Tighten clutch cover bolts to 52 N⅐m (38 ft. lbs.)
11. ZJ CLUTCH SERVICE 6 - 11
(11) Install transmission-clutch housing assembly. (3) Lubricate release bearing bore, release lever
Refer to Figure 4 for attaching bolt torques. and pivot ball contact surfaces with Mopar high tem-
perature grease.
(4) Transfer pivot ball stud, release lever, boot, and
release bearing to new housing.
(5) Clean transmission and clutch housing mount-
ing faces with solvent. Be sure all dirt, grease, oil are
removed completely. Surfaces must be clean to en-
sure proper seating and avoid housing misalignment.
(6) Align and install clutch housing on transmis-
sion. Tighten housing bolts to 33-43 N⅐m (24-32 ft.
lbs.) torque.
(7) Install transmission as described in Group 21.
Install transmission-to-engine struts after clutch
housing has been installed. Tighten bolts attaching
struts to clutch housing first and strut-to-engine
bolts last.
Fig. 4 Transmission/Clutch Housing Installation RELEASE BEARING REPLACEMENT
(1) Remove transmission and clutch housing as an
CLUTCH HOUSING REMOVAL
assembly.
(1) Raise vehicle and remove transmission and
(2) Disconnect release bearing from lever and re-
clutch housing as assembly. move bearing (Fig. 5).
(2) Remove release bearing, release lever, boot, and (3) Inspect bearing slide surface of transmission
lever ball stud from clutch housing (Fig. 5). front bearing retainer. Replace retainer if slide sur-
(3) Remove clutch housing attaching bolts and re- face is scored, worn, or cracked.
move housing from transmission (Fig. 5). (4) Inspect release lever and lever pivot ball stud.
Be sure pivot is secure and in good condition. Be sure
CLUTCH HOUSING INSTALLATION lever is not distorted or worn. Replace release lever
(1) Clean housing mounting surface of engine block retainer spring if bent or damaged in any way.
with solvent. (5) Lightly lubricate contact/pivot points of follow-
(2) Check alignment dowels in engine block. Be ing parts with Mopar high temperature grease:
sure dowels are in good condition and properly • crankshaft pilot bearing
seated. • transmission input shaft splines
Fig. 5 Clutch Housing And Release Bearing Attachment
12. 6 - 12 CLUTCH SERVICE ZJ
• transmission bearing retainer slide surface CLUTCH HYDRAULIC LINKAGE REMOVAL
• release lever The clutch master cylinder and pedal position
• release lever pivot stud switch, remote reservoir, slave cylinder, and
(6) Install release lever and new release bearing. connecting lines are only available as a com-
Be sure lever and bearing are properly secured. plete assembly. The linkage components cannot
(7) Install transmission and clutch housing as as- be overhauled or serviced separately. The cylin-
sembly. ders and connecting lines are sealed units.
(1) Raise vehicle.
PILOT BEARING REPLACEMENT (2) Remove nuts attaching slave cylinder to clutch
(1) Remove transmission and clutch housing.
housing.
(2) Remove clutch cover and disc.
(3) Remove slave cylinder and clip from housing.
(3) Remove pilot bearing. Use blind hole puller
(4) Disengage hydraulic fluid line from body clips.
tools such as those included in Snap-On set CG40CB
to remove bearing. (5) Lower vehicle.
(4) Clean bearing bore with solvent and wipe dry (6) Remove retaining ring, flat washer and wave
with shop towel. washer that attach clutch master cylinder push rod
(5) Lubricate new pilot bearing with Mopar high to clutch pedal (Fig. 7).
temperature grease. (7) Disconnect clutch pedal position switch wires.
(6) Position and start new bearing in bearing bore Then slide clutch master cylinder piston rod off
by hand. Note that pilot bearing has seal at one clutch pedal pin.
end. Install bearing so seal is facing out and to- (8) Inspect condition of bushing on clutch pedal
ward transmission. pin. Remove and replace bushing if worn or dam-
(7) Seat pilot bearing with clutch alignment tool aged.
(Fig. 6). Keep bearing straight during installa- (9) Verify that cap on clutch master cylinder reser-
tion. Do not allow bearing to become cocked. voir is tight. This is necessary to avoid undue spill-
Tap bearing into place until flush with edge of age during removal.
bearing bore. Do not recess bearing. (10) Remove screws attaching clutch fluid reservoir
to dash panel.
(11) Remove nuts attaching clutch master cylinder
to stud nuts (Fig. 7).
(12) Remove both clutch cylinders, reservoir and
connecting line from vehicle.
CLUTCH HYDRAULIC LINKAGE INSTALLATION
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser-
voir in vehicle.
(3) Install clutch master cylinder on mounting
studs extending through dash panel (Fig. 7). Tighten
attaching nuts to 23-34 N⅐m (200-300 in. lbs.) torque.
(4) Position reservoir on dash panel and install
reservoir screws. Tighten screws to 5 N⅐m (40 in. lbs.)
torque.
(5) Install replacement bushing on clutch pedal pin
if necessary.
(6) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
Fig. 6 Pilot Bearing Installation (7) Connect clutch pedal position switch wires.
(8) Install clutch cover and disc. (8) Raise vehicle.
(9) Install clutch housing and transmission as as- (9) Insert slave cylinder push rod through clutch
sembly. housing opening and into release lever. Be sure cap
(10) Install transfer case, propeller shafts, wire on end of rod is securely engaged in lever. Check this
harnesses, vacuum hoses, crossmembers, shift link- before installing cylinder attaching nuts.
age and remaining components removed during ser- (10) Install and tighten slave cylinder attaching
vice. nuts to 23-34 N⅐m (200-300 in. lbs.) torque.
13. ZJ CLUTCH SERVICE 6 - 13
Fig. 7 Clutch Hydraulic Linkage Components
(11) Insert clutch fluid line in body clips and lower (5) Secure push rod to pedal pin with wave washer,
vehicle. flat washer and retaining ring.
(6) Connect clutch pedal position switch wires.
CLUTCH PEDAL REMOVAL
(1) Disconnect clutch pedal position switch wires.
(2) Remove retaining ring, flat washer and wave
washer that secure clutch master cylinder push rod
to clutch pedal pin (Fig. 8).
(3) Remove fastener that secures pedal shaft to
pedal support.
(4) Slide pedal shaft out left side of pedal support
and out of clutch pedal.
(5) Slide push rod off clutch pedal pin and remove
clutch pedal.
(6) Remove and inspect bushings in clutch pedal
shaft bore and on bushing on pedal pin. Replace any
bushing that is worn or damaged.
CLUTCH PEDAL INSTALLATION
(1) Lubricate pedal shaft, pedal shaft bore and all
bushings with generous quantity of Mopar multi-
mileage, or high temp grease.
(2) Insert pedal pin into cylinder push rod. Then
position clutch pedal in support.
(3) Slide pedal shaft through clutch pedal bore and
Fig. 8 Clutch Pedal Mounting
bushings.
(4) Install bolt that retains pedal shaft in support.
14. 6 - 14 CLUTCH SERVICE ZJ
FLYWHEEL SERVICE Ring Gear Replacement
Inspect the flywheel whenever the clutch disc, (1) Mark position of the old gear for alignment ref-
cover and housing are removed for service. Check erence on the flywheel. Use a scriber for this pur-
condition of the flywheel face, hub, ring gear teeth, pose.
and flywheel bolts. (2) Wear protective goggles or approved safety
Minor scratches, burrs, or glazing on the flywheel glasses. Also wear heat resistent gloves when han-
face can be scuff sanded with 120/180 grit emery dling a heated ring gear.
cloth. However, the flywheel should be replaced if the (3) Remove the old gear by cutting most of the way
disc contact surface is severely scored, heat checked, through it (at one point) with an abrasive cut-off
cracked, or obviously worn. wheel. Then complete removal with a cold chisel or
Cleanup of minor flywheel scoring should be per- punch.
formed with surface grinding equipment. Remove (4) The ring gear is a shrink fit on the flywheel.
only enough material to reduce scoring (approximate-
This means the gear must be expanded by heating in
ly 0.001 - 0.003 in. maximum).
order to install it. The method of heating and ex-
Heavy stock removal from the flywheel face is
panding the gear is extremely important. Every
not recommended. Replace the flywheel if scor-
surface of the gear must be heated at the same time
ing is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in fly- to produce uniform expansion. An oven or similar en-
wheel cracking or warpage after installation. It closed heating device must be used. Temperature re-
can also weaken the flywheel and interfere quired for uniform expansion is 325-350° F. Heating
with proper clutch release. time is approximately 30 minutes.
Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm (0.003 CAUTION: Never use an oxy/acetylene torch to re-
in.). Measure runout at the outer edge of the fly- move the old gear, or to heat and expand a new
wheel face with a dial indicator. Mount the dial indi- gear. The high temperature of the torch flame will
cator on a stud installed in place of one of the cause localized heating and damage the flywheel. In
flywheel attaching bolts. addition, using the torch to heat a replacement gear
Clean the crankshaft flange before mounting the will cause uneven heating and expansion. The torch
flywheel. Dirt and grease on the flange surface may flame will also anneal the gear teeth resulting in
cock the flywheel causing excessive runout. rapid wear and damage after installation.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks (5) The heated gear must be installed evenly to
in the area of the attaching bolt holes. avoid misalignment or distortion. A shop press and
Install new attaching bolts whenever the flywheel suitable press plates should be used to install the
is replaced and use Mopar Lock N’ Seal, or Loctite gear if at all possible.
242 on replacement bolt threads. (6) Be sure to wear eye and hand protection. Heat
Recommended flywheel bolt torque is 142 N⅐m (105 resistent gloves and safety goggles are needed for
ft. lbs.). personal safety. Use metal tongs, vise grips, or simi-
lar tools to handle the hot gear during installation.
STARTER RING GEAR SERVICE (7) Allow the flywheel and ring gear to cool down
Inspect the teeth on the starter ring gear. If the before installation. Set the assembly on a workbench
teeth are worn or damaged, the flywheel should and let it cool in normal shop air.
be replaced as an assembly. This is the recom-
mended and preferred method of repair. CAUTION: Never use water, or compressed air to
In cases where a new flywheel is not readily cool the new ring gear. The rapid cooling produced
available, a replacement ring gear can be in- by water or compressed air can distort, or crack the
stalled. However, the following precautions ring gear and flywheel.
must be observed to avoid damaging the fly-
wheel and replacement gear.
