Jeep Wrangler TJ. Manual — part 259
(10) Disconnect
clutch
interlock
safety
switch
wires.
(11) Remove
clutch
hydraulic
linkage
through
engine compartment.
INSTALLATION
NOTE: Clutch master cylinder, slave cylinder and
connecting line are serviced as an assembly only.
Components cannot be overhauled or serviced sep-
arately. Cylinders and connecting line are sealed
units.
Removal/installation procedures for right and left
hand drive models are basically the same.
(1) Tighten clutch master cylinder cap.
(2) Position connecting line and slave cylinder
downward past engine and next to clutch housing.
(3) Position clutch master cylinder on dash panel.
(4) Install clutch master cylinder actuator on
clutch pedal pivot pin.
(5) Install clutch master cylinder and tighten nuts
to 38 N·m (28 ft. lbs.).
(6) 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.
(7) Install slave cylinder and tighten nuts to 23
N·m (17 ft. lbs.).
(8) Secure clutch fluid line in body and transmis-
sion clips.
(9) Connect clutch interlock safety switch wires.
MASTER CYLINDER
INSPECTION
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are pre-filled at the factory.
The hydraulic system should not require additional
fluid under normal circumstances. The reservoir fluid
level increases as clutch wear occurs.
CAUTION: Do not overfill or removing fluid from the
reservoir. Failure to heed caution may result in
damage.
Wipe reservoir and cover clean. Remove cap and
diaphragm, fluid level should not be above indicator
ring located on the outside of the reservoir.
Fig. 7 CLUTCH LINKAGE - LHD
1 - CLUTCH HOUSING
2 - FLUID LINE
3 - BRACKET
4 - FLUID LINE
5 - CLIP
6 - CAPTURED BUSHING
7 - CLUTCH SLAVE CYLINDER
8 - CLUTCH MASTER CYLINDER
9 - DASH PANEL
Fig. 8 CLUTCH LINKAGE - RHD
1 - DASH PANEL
2 - FLUID LINE
3 - CLIP
4 - HOLD DOWN STRAP
5 - CLUTCH MASTER CYLINDER
6 - CAPTURED BUSHING
TJ
CLUTCH
6 - 9
LINKAGE (Continued)
CLUTCH PEDAL
REMOVAL
(1) Remove steering column lower cover and knee
blocker for access.
(2) Disconnect clutch pedal position switch wires.
(3) Disengage captured bushing lock tabs attach-
ing clutch master cylinder actuator to pedal pivot
(Fig. 9) or (Fig. 10).
(4) Remove nuts attaching pedal and bracket to
dash panel and upper cowl support (Fig. 9) or (Fig.
10).
(5) Separate pedal assemble from vehicle.
INSTALLATION
(1) Place clutch pedal and bracket over studs on
dash panel and cowl support. Install nuts and
tighten to 39 N·m (29 ft. lbs.).
(2) Engage captured bushing and actuator on
brake pedal pivot.
(3) Connect clutch pedal position switch wires.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The Clutch Pedal Position Switch (CPPS) is located
under the instrument panel, attached to the clutch
master cylinder push rod (Fig. 11). The wiring har-
ness connector is inside of the vehicle under the left
side of the instrument panel (Fig. 12).
NOTE: Switch is serviced with clutch master cylin-
der only.
Fig. 9 CLUTCH PEDAL MOUNTING - LHD
1 - CLUTCH CYLINDER ACTUATOR
2 - CAPTURED BUSHING
3 - UPPER COWL SUPPORT
4 - PIVOT
5 - CLUTCH PEDAL
6 - BRACKET
7 - DASH PANEL
Fig. 10 CLUTCH PEDAL MOUNTING - RHD
1 - CLUTCH CYLINDER ACTUATOR
2 - CAPTURED BUSHING
3 - UPPER COWL SUPPORT
4 - PIVOT
5 - CLUTCH PEDAL
6 - BRACKET
7 - DASH PANEL
Fig. 11 CLUTCH PEDAL POSITION SWITCH (CPPS)
1 - INSTRUMENT PANEL
2 - SWITCH WIRING HARNESS
3 - CLUTCH PEDAL POSITION SWITCH
4 - CLUTCH MASTER CYLINDER
6 - 10
CLUTCH
TJ
OPERATION
The clutch pedal position switch is used to prevent
starter motor engagement unless the clutch pedal is
depressed. An input from this switch is also used to
either shut down/prevent operation of the speed con-
trol system when pedal is depressed.
DIAGNOSIS AND TESTING
(1) Disconnect
2-wire
switch
connector
under
instrument panel (Fig. 13).
(2) Check switch continuity with an ohmmeter
while operating clutch pedal.
• Pedal Depressed - Continuity
• Pedal Released - No Continuity
(3) If continuity is not present or always present,
replace clutch master cylinder. Switch is not serviced
separately.
Fig. 12 CPPS ELECTRICAL CONNECTION
1 - CPPS CONNECTION TO MAIN HARNESS
Fig. 13 CPPS ELECTRICAL CONNECTION
1 - CPPS CONNECTION TO MAIN HARNESS
TJ
CLUTCH
6 - 11
CLUTCH PEDAL POSITION SWITCH (Continued)
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