TJ CLUTCH 6-1

CLUTCH
CONTENTS

page page

GENERAL INFORMATION CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 9

CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . 1 CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . . 9
CLUTCH INTERLOCK SAFETY SWITCH FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BY-PASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
INSTALLATION METHODS AND CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 10
PARTS USAGE . . . . . . . . . . . . . . . . . . . . . . . . . 1 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION AND OPERATION CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . 12
CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . 2 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES SPECIFICATIONS
CLUTCH COMPONENT LUBRICATION . . . . . . . . 9 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

GENERAL INFORMATION adjacent to the brake master cylinder and booster

assembly. This positioning is similar for both left and
CLUTCH COMPONENTS right hand drive models.
The clutch mechanism in TJ models consists of a
single, dry-type disc and a diaphragm style clutch INSTALLATION METHODS AND PARTS USAGE
cover. A hydraulic linkage is used to operate the Distortion of clutch components during installation
clutch release bearing and fork. and the use of non-standard components are common
A needle-type pilot bearing supports the transmis- causes of clutch malfunction.
sion input shaft in the crankshaft. A conventional Improper clutch cover bolt tightening can distort
release bearing is used to engage and disengage the the cover. The usual result is clutch grab, chatter
clutch cover pressure plate. and rapid wear. Tighten the cover bolts as described
The release bearing is operated by a release fork in in Removal and Installation section.
the clutch housing. The fork pivots on a ball stud An improperly seated flywheel and/or clutch hous-
mounted in the housing. The release fork is actuated ing are additional causes of clutch failure. Improper
by a hydraulic slave cylinder mounted on the hous- seating will produce misalignment and additional
ing. The slave cylinder is operated by a clutch master clutch problems.
cylinder mounted on the dash panel. The cylinder The use of non-standard or low quality parts will
push rod is connected to the clutch pedal. also lead to problems and wear. Use recommended
The clutch disc has cushion springs in the disc factory quality parts to avoid comebacks.
hub. The clutch disc facing is riveted to the hub. The A cocked pilot bearing is another cause of clutch
facing is made from a non-asbestos material. The noise, drag, hard shifting, and rapid bearing wear.
clutch cover pressure plate is a diaphragm type with Always use an alignment tool to install a new bear-
a one-piece spring and multiple release fingers. The ing. This practice helps avoid cocking the bearing
pressure plate release fingers are preset during man- during installation.
ufacture and are not adjustable.
CLUTCH INTERLOCK SAFETY SWITCH BY-PASS
HYDRAULIC LINKAGE COMPONENTS
The hydraulic linkage consists of a clutch master WARNING: This procedure is intended for use only
cylinder with integral reservoir, a clutch slave cylin- off-road. When the vehicle is returned to road use,
der and an interconnecting fluid line. properly connect the clutch interlock safety switch.
The clutch master cylinder push rod is connected Dangerous conditions may result.
to the clutch pedal. The slave cylinder push rod is
connected to the clutch release fork. The master cyl- The Clutch Interlock Safety Switch will inhibit the
inder is mounted on the driver side of the dash panel starter cranking circuit until the clutch pedal is
6-2 CLUTCH TJ
GENERAL INFORMATION (Continued)
depressed. In some off-road situations this safety fea- The clutch linkage uses hydraulic pressure to oper-
ture is not desirable. ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
BY-PASS PROCEDURE push rod is connected to the release lever in the
(1) Disengage wire connector from clutch interlock clutch housing.
safety switch, located under the instrument panel Depressing the clutch pedal develops fluid pressure
next to the 100–way connector (Fig. 1). in the clutch master cylinder. This pressure is trans-
(2) Locate open by-pass connector, located next to mitted to the slave cylinder through a connecting
the 100–way connector. line. In turn, the slave cylinder operates the clutch
(3) Engage clutch interlock switch harness connec- release lever.
tor into by-pass connector (Fig. 1). The clutch release bearing is mounted on the
Reverse the preceding procedure to activate the transmission front bearing retainer. The bearing is
Clutch Interlock Safety Switch. attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.
Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and freewheeling at this
point.
The process of clutch re-engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
Fig. 1 Clutch Interlock Safety Switch By-Pass
DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING

CLUTCH OPERATION DIAGNOSTIC INFORMATION

Leverage, clamping force, and friction are what Unless the cause of a clutch problem is obvious,
make the clutch work. The disc serves as the friction accurate problem diagnosis will usually require a
element and a diaphragm spring and pressure plate road test to confirm a problem. Component inspection
provide the clamping force. The clutch pedal, hydrau- (Fig. 2) will then be required to determine the actual
lic linkage, release lever and bearing provide the problem cause.
leverage. During a road test, drive the vehicle at normal
The clutch cover assembly clamps the disc against speeds. Shift the transmission through all gear
the flywheel. The assembly consists of the cover, dia- ranges and observe clutch action. If chatter, grab,
phragm spring, pressure plate, and fulcrum compo- slip, or improper release is experienced, remove and
nents. The pressure plate clamps the clutch disc inspect the clutch components. However, if the prob-
against the flywheel and the spring provides the lem is noise or hard shifting, further diagnosis may
clamping force. be needed as the transmission or another driveline
The clutch disc friction material is riveted to the component may be at fault. Careful observation dur-
disc hub. The hub bore is splined for installation on ing the test will help narrow the problem area.
the transmission input shaft. The hub splines con-
nect the disc to the transmission.
TJ CLUTCH 6-3
DIAGNOSIS AND TESTING (Continued)

Fig. 2 Clutch Components And Inspection

6-4 CLUTCH TJ
DIAGNOSIS AND TESTING (Continued)
CLUTCH CONTAMINATION weaken the flywheel and interfere with proper clutch
Fluid contamination is a frequent cause of clutch release.
malfunctions. Oil, water, or clutch fluid on the clutch Clean the crankshaft flange before mounting the
disc and pressure plate surfaces will cause chatter, flywheel. Dirt and grease on the flange surface may
slip and grab. cock the flywheel causing excessive runout. Use new
During inspection, note if any components are con- bolts when remounting a flywheel and secure the
taminated with oil, hydraulic fluid, or water/road bolts with Mopart Lock And Seal. Tighten flywheel
splash. bolts to specified torque only. Overtightening can dis-
Oil contamination indicates a leak at either the tort the flywheel hub causing runout.
rear main seal or transmission input shaft. Oil leak-
age produces a residue of oil on the housing interior CLUTCH COVER AND DISC RUNOUT
and on the clutch cover and flywheel. Heat buildup Check the clutch disc before installation. Axial
caused by slippage between the cover, disc and fly- (face) runout of a new disc should not exceed 0.50
wheel, can sometimes bake the oil residue onto the mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
components. The glaze-like residue ranges in color from the outer edge of the disc facing. Obtain
from amber to black. another disc if runout is excessive.
Road splash contamination means dirt/water is Check condition of the clutch before installation. A
entering the clutch housing due to loose bolts, hous- warped cover or diaphragm spring will cause grab
ing cracks, or through hydraulic line openings. Driv- and incomplete release or engagement. Be careful
ing through deep water puddles can force water/road when handling the cover and disc. Impact can distort
splash into the housing through such openings. the cover, diaphragm spring, release fingers and the
Clutch fluid leaks are usually from damaged slave hub of the clutch disc.
cylinder push rod seals. This type of leak can only be Use an alignment tool when positioning the disc on
confirmed by visual inspection. the flywheel. The tool prevents accidental misalignment
which could result in cover distortion and disc damage.
CLUTCH MISALIGNMENT A frequent cause of clutch cover distortion (and con-
Clutch components must be in proper alignment sequent misalignment) is improper bolt tightening.
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage CLUTCH HOUSING MISALIGNMENT
of any clutch component will cause grab, chatter and Clutch housing alignment is important to proper
improper clutch release. clutch operation. The housing maintains alignment
between the crankshaft and transmission input
FLYWHEEL RUNOUT shaft. Misalignment can cause clutch noise, hard
Check flywheel runout whenever misalignment is shifting, incomplete release and chatter. It can also
suspected. Flywheel runout should not exceed 0.08 result in premature wear of the pilot bearing, cover
mm (0.003 in.). Measure runout at the outer edge of release fingers and clutch disc. In severe cases, mis-
the flywheel face with a dial indicator. Mount the alignment can also cause premature wear of the
indicator on a stud installed in place of one of the fly- transmission input shaft and front bearing.
wheel bolts. Housing misalignment is generally caused by
Common causes of runout are: incorrect seating on the engine or transmission, loose
• heat warpage housing bolts, missing alignment dowels, or housing
• improper machining damage. Infrequently, misalignment may also be
• incorrect bolt tightening caused by housing mounting surfaces that are not
• improper seating on crankshaft flange shoulder completely parallel. Misalignment can be corrected
• foreign material on crankshaft flange with shims.
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour INSPECTION AND DIAGNOSIS CHARTS
and machining will negate this feature. However, The clutch inspection chart (Fig. 2) outlines items to
minor flywheel scoring can be cleaned up by hand be checked before and during clutch installation. Use
with 180 grit emery, or with surface grinding equip- the chart as a check list to help avoid overlooking
ment. Remove only enough material to reduce scor- potential problem sources during service operations.
ing (approximately 0.001 - 0.003 in.). Heavy stock The diagnosis charts describe common clutch prob-
removal is not recommended. Replace the flywheel lems, causes and correction. Fault conditions are listed
if scoring is severe and deeper than 0.076 mm (0.003 at the top of each chart. Conditions, causes and correc-
in.). Excessive stock removal can result in flywheel tive action are outlined in the indicated columns.
cracking or warpage after installation; it can also The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
TJ CLUTCH 6-5
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART
6-6 CLUTCH TJ
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART (CONT.)
TJ CLUTCH 6-7
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART (CONT.)
6-8 CLUTCH TJ
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART (CONT.)
TJ CLUTCH 6-9

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. Fig. 3 Clutch Master Cylinder Reservoir And Cap
• Input shaft splines. FLYWHEEL
• Input shaft pilot hub. Inspect the flywheel whenever the clutch disc,
• Transmission front bearing retainer cover and housing are removed for service. Check
slide surface. condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
NOTE: Never apply grease to any part of the clutch
Minor scratches, burrs, or glazing on the flywheel
cover, or disc.
face can be reduced with 180 grit emery cloth. How-
ever, the flywheel should be replaced if the disc con-
RECOMMENDED LUBRICANTS tact surface is severely scored, heat checked, cracked,
Use Mopart multi-purpose grease for the clutch or obviously worn.
pedal bushings and pivot shaft. Use Mopart high Flywheel machining is not recommended. The fly-
temperature grease (or equivalent) for all other lubri- wheel surface is manufactured with a unique contour
cation requirements. Apply recommended amounts that would be negated by machining. However,
and do not over lubricate. cleanup of minor flywheel scoring can be performed
by hand with 180 grit emery, or with surface grind-
CLUTCH LINKAGE FLUID ing equipment. Replace the flywheel if scoring is
If inspection or diagnosis indicates additional fluid deeper than 0.0762 mm (0.003 in.).
may be needed, use Mopart brake fluid, or an equiv- Heavy stock removal by grinding is not recom-
alent meeting standards SAE J1703 and DOT 3. Do mended. Excessive stock removal can result in fly-
not use any other type of fluid. wheel cracking or warpage after installation. It can
also weaken the flywheel and interfere with proper
CLUTCH FLUID LEVEL clutch release.
The clutch fluid reservoir, master cylinder, slave Check flywheel runout if misalignment is sus-
cylinder and fluid lines are pre-filled with fluid at pected. Runout should not exceed 0.08 mm (0.003
the factory during assembly operations. in.). Measure runout at the outer edge of the fly-
The hydraulic system should not require additional wheel face with a dial indicator. Mount the dial indi-
fluid under normal circumstances. The reservoir cator on a stud installed in place of one of the clutch
fluid level will actually increase as normal housing attaching bolts.
clutch wear occurs. Avoid overfilling, or remov- Clean the crankshaft flange before mounting the
ing fluid from the reservoir. flywheel. Dirt and grease on the flange surface may
Clutch fluid level is checked at the master cylinder cock the flywheel causing excessive runout.
reservoir (Fig. 3). An indicator ring is provided on the Check condition of the flywheel hub and attaching
outside of the reservoir. With the cap and diaphragm bolts. Replace the flywheel if the hub exhibits cracks
removed, fluid level should not be above indicator in the area of the attaching bolt holes.
ring. Install new attaching bolts whenever the flywheel
To avoid contaminating the hydraulic fluid during is replaced and use Mopart Lock N’ Seal, or Loctite
inspection, wipe reservoir and cover clean before 242 on the replacement bolt threads.
removing the cap. Recommended flywheel bolt torques are:
• 142 N·m (105 ft. lbs.) for 6-cylinder flywheels
6 - 10 CLUTCH TJ
SERVICE PROCEDURES (Continued)
• 68 N·m (50 ft. lbs.) plus an additional turn of REMOVAL AND INSTALLATION
60° for 4-cylinder flywheels
Inspect the teeth on the starter ring gear. If the CLUTCH COVER AND DISC
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom- REMOVAL
mended and preferred method of repair. (1) Remove transmission. Refer to procedures in
In cases where a new flywheel is not readily avail- Group 21.
able, a replacement ring gear can be installed. How- (2) If original clutch cover will be reinstalled, mark
ever, the following precautions must be observed to position of cover on flywheel for assembly reference.
avoid damaging the flywheel and replacement gear. Use paint or a scriber for this purpose.
(1) Mark position of the old gear for alignment ref- (3) If clutch cover is to be replaced, cover bolts can
erence on the flywheel. Use a scriber for this pur- be removed in any sequence. However, if original
pose. cover will be reinstalled, loosen cover bolts evenly
(2) Wear protective goggles or approved safety and in rotation to relieve spring tension equally. This
glasses. Also wear heat resistent gloves when han- is necessary to avoid warping cover.
dling a heated ring gear. (4) Remove cover bolts and remove cover and disc
(3) Remove the old gear by cutting most of the way (Fig. 4).
through it (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or INSTALLATION
punch. (1) Lightly scuff sand flywheel face with 180 grit
(4) The ring gear is a shrink fit on the flywheel. emery cloth. Then clean surface with a wax and
This means the gear must be expanded by heating in grease remover.
order to install it. The method of heating and (2) Lubricate pilot bearing with Mopar high tem-
expanding the gear is extremely important. perature bearing grease.
Every surface of the gear must be heated at the same (3) Check runout and free operation of new clutch
time to produce uniform expansion. An oven or simi- disc as follows:
lar enclosed heating device must be used. Tempera- (a) Slide disc onto transmission input shaft
ture required for uniform expansion is approximately splines. Disc should slide freely on splines.
375° F. (b) Leave disc on shaft and check face runout
with dial indicator. Check runout at disc hub and
CAUTION: Do not use an oxy/acetylene torch to about 6 mm (1/4 in.) from outer edge of facing.
remove the old gear, or to heat and expand a new (c) Face runout should not exceed 0.5 mm (0.020
gear. The high temperature of the torch flame can in.). Obtain another clutch disc if runout exceeds
cause localized heating that will damage the fly- this limit.
wheel. In addition, using the torch to heat a replace- (4) Position clutch disc on flywheel. Be sure side of
ment gear will cause uneven heating and disc marked flywheel side is positioned against fly-
expansion. The torch flame can also anneal the wheel (Fig. 4). If disc is not marked, be sure flat side
gear teeth resulting in rapid wear and damage after of disc hub is toward flywheel.
installation. (5) Inspect condition of pressure plate surface of
clutch cover (Fig. 4). Replace cover if this surface is
(5) The heated gear must be installed evenly to worn, heat checked, cracked, or scored.
avoid misalignment or distortion. A shop press and (6) Insert clutch alignment tool in clutch disc (Fig.
suitable press plates should be used to install the 5).
gear if at all possible. (7) Insert alignment tool in pilot bearing and posi-
(6) Be sure to wear eye and hand protection. Heat tion disc on flywheel. Be sure disc hub is positioned
resistent gloves and safety goggles are needed for correctly. Side of hub marked Flywheel Side should
personal safety. Also use metal tongs, vise grips, or face flywheel (Fig. 4). If disc is not marked, place flat
similar tools to position the gear as necessary for side of disc against flywheel.
installation. (8) Position clutch cover over disc and on flywheel
(7) Allow the flywheel and ring gear to cool down (Fig. 5).
before installation. Set the assembly on a workbench (9) Install clutch cover bolts finger tight.
and let it cool in normal shop air. (10) Tighten cover bolts evenly and in rotation a
few threads at a time. Cover bolts must be tight-
CAUTION: Do not use water, or compressed air to ened evenly and to specified torque to avoid
cool the flywheel. The rapid cooling produced by distorting cover. Tightening torques are 31 N·m
water or compressed air can distort, or crack the (23 ft. lbs.) on 2.5L engines and 52 N·m (38 ft.
gear and flywheel. lbs.) on 4.0 L engines.
TJ CLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)
(2) Disconnect release bearing from release lever
and remove bearing (Fig. 6).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(4) Inspect release fork and fork pivot. 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.

INSTALLATION
(1) Lubricate crankshaft pilot bearing with Mopart
high temperature bearing grease. Apply grease to
end of long shank, small diameter flat blade screw-
driver. Then insert tool through clutch disc hub to
reach bearing.
Fig. 4 Clutch Disc And Pressure Plate Inspection (2) Lubricate input shaft splines, bearing retainer
slide surface, fork pivot and release fork pivot surface
with Mopart high temperature grease.
(3) Install new release bearing. Be sure bearing is
properly secured to release fork.
(4) Install transmission.

Fig. 5 Typical Method Of Aligning Clutch Disc

(a) Start all 6 bolts by hand.
(b) Tighten 3 pilot hole bolts 3/4s of the way
(any sequence).
(c) Starting 180 degrees from the last pilot bolt,
Fig. 6 Release Bearing Attachment
tighten 3 large hole bolts 3/4s of the way (any
sequence). PILOT BEARING
(d) Tighten 3 pilot hole bolts all the way (any
sequence). REMOVAL
(e) Starting 180 degrees from last pilot bolt, (1) Remove transmission.
tighten 3 large bolts all the way (any sequence). (2) Remove clutch cover and disc.
(11) Apply light coat of Mopart high temperature (3) Remove pilot bearing. Use internal (blind hole)
bearing grease to clutch disc hub and splines of puller such those as supplied in Snap–Ont Tool Set
transmission input shaft. Do not over lubricate CG40CB to remove bearing.
shaft splines. This will result in grease contam-
ination of disc. INSTALLATION
(12) Install transmission. (1) Lubricate new bearing with Mopart high tem-
perature bearing grease.
RELEASE BEARING (2) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool (Fig. 7).
REMOVAL (3) Lightly scuff sand flywheel surface with 180
(1) Remove transmission. grit emery cloth. Then clean surface with wax and
grease remover.
6 - 12 CLUTCH TJ
REMOVAL AND INSTALLATION (Continued)

Fig. 7 Pilot Bearing Installation

(4) Install clutch disc and cover as described in
this section.
(5) Install transmission.

CLUTCH HOUSING
The clutch housing is removable and can be
replaced when the transmission is out of the vehicle.
The bolts attaching the housing to the transmis-
sion case are located inside the housing (Fig. 8). Rec-
ommended tightening torque for the clutch housing-
to-transmission bolts is 38 N·m (28 ft. lbs.). Fig. 8 Clutch Housing Attachment
NOTE: Be sure the transmission and housing mat- (6) Verify that cap on clutch master cylinder reser-
ing surfaces are clean before installing an original, voir is tight. This is necessary to avoid spilling fluid
or replacement clutch housing. Dirt/foreign material during removal.
trapped between the housing and transmission will (7) Remove clutch master cylinder attaching nuts
cause misalignment. If misalignment is severe (Fig. 9) or (Fig. 10).
enough, the result will be clutch drag, incomplete (8) Disengage captured bushing on clutch master
release and hard shifting. cylinder actuator from pivot pin on pedal arm.
(9) Slide actuator off pivot pin.
(10) Disconnect clutch interlock safety switch
CLUTCH HYDRAULIC LINKAGE wires.
The clutch master cylinder, slave cylinder and con- (11) Remove clutch hydraulic linkage through
necting line are serviced as an assembly only. The engine compartment.
linkage components cannot be overhauled or serviced
separately. The cylinders and connecting line are INSTALLATION
sealed units. Also note that removal/installation pro- (1) Be sure reservoir cover on clutch master cylin-
cedures for right and left hand drive models are basi- der is tight to avoid spills.
cally the same. Only master cylinder location is (2) Position clutch linkage components in vehicle.
different. Work connecting line and slave cylinder downward
past engine and adjacent to clutch housing (Fig. 9) or
REMOVAL (Fig. 10).
(1) Raise vehicle. (3) Position clutch master cylinder on dash panel
(2) Remove fasteners attaching slave cylinder to (Fig. 9) or (Fig. 10).
clutch housing. (4) Attach clutch master cylinder actuator to pivot
(3) Remove slave cylinder from clutch housing pin on clutch pedal.
(Fig. 9). (5) Install and tighten clutch master cylinder
(4) Disengage clutch fluid line from body clips. attaching nuts to 38 N·m (28 ft. lbs.) torque.
(5) Lower vehicle. (6) Raise vehicle.
TJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
(3) Disengage captured bushing lock tabs attach-
ing clutch master cylinder actuator to pedal pivot
(Fig. 11) or (Fig. 12).
(4) Remove nuts attaching pedal and bracket to
dash panel and upper cowl support (Fig. 11) or (Fig.
12).
(5) Separate pedal assemble from vehicle.

INSTALLATION
(1) Place clutch pedal and bracket over studs on
dash panel and cowl support (Fig. 11) or (Fig. 12).
(2) Install nuts to attach pedal and bracket to
dash panel and upper cowl support (Fig. 11) or (Fig.
12). Tighten nuts to 39 N·m (29 ft. lbs.) torque
(3) Engage captured bushing and actuator on
brake pedal pivot (Fig. 11) or (Fig. 12).
Fig. 9 Slave Cylinder and Left Hand Drive Clutch (4) Connect clutch pedal position switch wires.
Master Cylinder

Fig. 11 Clutch Pedal Mounting

Fig. 10 Right Hand Drive Clutch Master Cylinder
(7) Insert slave cylinder push rod through clutch
housing opening and into release lever. Be sure cap
on end of rod is securely engaged in lever. Check this
before installing cylinder attaching nuts.
(8) Install and tighten slave cylinder attaching
nuts to 23 N·m (17 ft. lbs.) torque.
(9) Secure clutch fluid line in body and transmis-
sion clips.
(10) Lower vehicle.
(11) Connect clutch interlock safety switch wires.

CLUTCH PEDAL
REMOVAL
(1) Remove steering column lower cover and knee
blocker for access. Refer to Group 8E, Instrument
Panel for procedure.
(2) Disconnect clutch pedal position switch wires.
Fig. 12 Clutch Pedal Mounting—Right Hand Drive
6 - 14 CLUTCH TJ

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)
Nut, clutch master cyl. . . . . . . . . .38 N·m (28 ft. lbs)
Nut, clutch slave cyl. . . . . . . . . . . .23 N·m (17 ft. lbs)
Bolt, clutch housing M12 . . . . . . . .75 N·m (55 ft. lbs)
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)
Bolt, dust shield lower . . . . . . . . . .50 N·m (37 ft. lbs)
Bolt, X-member/frame . . . . . . . . . .41 N·m (30 ft. lbs)
Bolt, X-member/rear support . . . .45 N·m (33 ft. lbs.)
Bolts, flywheel 2.5 L . . . . . . . . . . .68 N·m (50 ft. lbs)
+1/4 turn
Bolts, flywheel 4.0 L . . . . . . . . .142 N·m (105 ft. lbs)