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Clutch

Clutch

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Published by aw12345

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Published by: aw12345 on Aug 17, 2009
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11/02/2010

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CLUTCH
CONTENTS
page page
GENERAL INFORMATION
DESCRIPTION AND OPERATION
CLUTCHOPERATION..................... 2
DIAGNOSIS AND TESTING
DIAGNOSTICINFORMATION............... 2
SERVICE PROCEDURES
CLUTCHCOMPONENTLUBRICATION........ 9CLUTCHFLUIDLEVEL.................... 9CLUTCHLINKAGEFLUID.................. 9FLYWHEEL............................. 9
REMOVAL AND INSTALLATION
CLUTCHCOVERANDDISC............... 10CLUTCHHOUSING...................... 12CLUTCHHYDRAULICLINKAGE............ 12CLUTCHPEDAL........................ 13PILOTBEARING........................ 11RELEASEBEARING..................... 11
SPECIFICATIONS
TORQUE.............................. 14
GENERAL INFORMATION
CLUTCH COMPONENTS
The clutch mechanism in TJ models consists of asingle, dry-type disc and a diaphragm style clutchcover. A hydraulic linkage is used to operate theclutch release bearing and fork.A needle-type pilot bearing supports the transmis-sion input shaft in the crankshaft. A conventionalrelease bearing is used to engage and disengage theclutch cover pressure plate.The release bearing is operated by a release fork inthe clutch housing. The fork pivots on a ball studmounted in the housing. The release fork is actuatedby a hydraulic slave cylinder mounted on the hous-ing. The slave cylinder is operated by a clutch mastercylinder mounted on the dash panel. The cylinderpush rod is connected to the clutch pedal.The clutch disc has cushion springs in the dischub. The clutch disc facing is riveted to the hub. Thefacing is made from a non-asbestos material. Theclutch cover pressure plate is a diaphragm type witha one-piece spring and multiple release fingers. Thepressure plate release fingers are preset during man-ufacture and are not adjustable.
HYDRAULIC LINKAGE COMPONENTS 
The hydraulic linkage consists of a clutch mastercylinder with integral reservoir, a clutch slave cylin-der and an interconnecting fluid line.The clutch master cylinder push rod is connectedto the clutch pedal. The slave cylinder push rod isconnected to the clutch release fork. The master cyl-inder is mounted on the driver side of the dash paneladjacent to the brake master cylinder and boosterassembly. This positioning is similar for both left andright hand drive models.
INSTALLATION METHODS AND PARTS USAGE
Distortion of clutch components during installationand the use of non-standard components are commoncauses of clutch malfunction.Improper clutch cover bolt tightening can distortthe cover. The usual result is clutch grab, chatterand rapid wear. Tighten the cover bolts as describedin Removal and Installation section.An improperly seated flywheel and/or clutch hous-ing are additional causes of clutch failure. Improperseating will produce misalignment and additionalclutch problems.The use of non-standard or low quality parts willalso lead to problems and wear. Use recommendedfactory quality parts to avoid comebacks.A cocked pilot bearing is another cause of clutchnoise, drag, hard shifting, and rapid bearing wear.Always use an alignment tool to install a new bear-ing. This practice helps avoid cocking the bearingduring installation.
CLUTCH INTERLOCK SAFETY SWITCH BY-PASS
WARNING: This procedure is intended for use onlyoff-road. When the vehicle is returned to road use,properly connect the clutch interlock safety switch.Dangerous conditions may result.
The Clutch Interlock Safety Switch will inhibit thestarter cranking circuit until the clutch pedal is
TJ
CLUTCH 6 - 1
 
depressed. In some off-road situations this safety fea-ture is not desirable.
BY-PASS PROCEDURE 
(1) Disengage wire connector from clutch interlocsafety switch, located under the instrument panelnext to the 100–way connector (Fig. 1).(2) Locate open by-pass connector, located next tothe 100–way connector.(3) Engage clutch interlock switch harness connec-tor into by-pass connector (Fig. 1).Reverse the preceding procedure to activate theClutch Interlock Safety Switch.
DESCRIPTION AND OPERATION
CLUTCH OPERATION
Leverage, clamping force, and friction are whatmake the clutch work. The disc serves as the frictionelement and a diaphragm spring and pressure plateprovide the clamping force. The clutch pedal, hydrau-lic linkage, release lever and bearing provide theleverage.The clutch cover assembly clamps the disc againstthe flywheel. The assembly consists of the cover, dia-phragm spring, pressure plate, and fulcrum compo-nents. The pressure plate clamps the clutch discagainst the flywheel and the spring provides theclamping force.The clutch disc friction material is riveted to thedisc hub. The hub bore is splined for installation onthe transmission input shaft. The hub splines con-nect the disc to the transmission.The clutch linkage uses hydraulic pressure to oper-ate the clutch. The clutch master cylinder push rod isconnected to the clutch pedal and the slave cylinderpush rod is connected to the release lever in theclutch housing.Depressing the clutch pedal develops fluid pressurein the clutch master cylinder. This pressure is trans-mitted to the slave cylinder through a connectingline. In turn, the slave cylinder operates the clutchrelease lever.The clutch release bearing is mounted on thetransmission front bearing retainer. The bearing isattached to the release lever, which moves the bear-ing into contact with the clutch cover diaphragmspring.Slave cylinder force causes the release lever tomove the release bearing into contact with the dia-phragm spring. As additional force is applied, thebearing presses the diaphragm spring fingers inwardon the fulcrums. This action moves the pressureplate rearward relieving clamp force on the disc. Theclutch disc is disengaged and freewheeling at thispoint.The process of clutch re-engagement is simply thereverse of what occurs during disengagement. Releas-ing pedal pressure removes clutch linkage pressure.The release bearing moves away from the diaphragmspring which allows the pressure plate to exertclamping force on the clutch disc.
DIAGNOSIS AND TESTING
DIAGNOSTIC INFORMATION
Unless the cause of a clutch problem is obvious,accurate problem diagnosis will usually require aroad test to confirm a problem. Component inspection(Fig. 2) will then be required to determine the actualproblem cause.During a road test, drive the vehicle at normalspeeds. Shift the transmission through all gearranges and observe clutch action. If chatter, grab,slip, or improper release is experienced, remove andinspect the clutch components. However, if the prob-lem is noise or hard shifting, further diagnosis maybe needed as the transmission or another drivelinecomponent may be at fault. Careful observation dur-ing the test will help narrow the problem area.
Fig. 1 Clutch Interlock Safety Switch By-Pass 
6 - 2 CLUTCH
TJ
GENERAL INFORMATION (Continued)
 
Fig. 2 Clutch Components And Inspection 
TJ
CLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

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