Jeep Liberty KJ. Manual — part 1377
CONDITION
POSSIBLE CAUSES
CORRECTION
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
3. Replace clutch disc.
4. Clutch misalignment.
4. Check alignment and runout of
flywheel, disc, pressure plate, and
clutch housing. Correct as
necessary.
SPECIFICATIONS
CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Pressure Plate Bolts -
3.7L
50
37
-
Pressure Plate Bolts -
2.5L Diesel
54
40
-
Clutch Cylinder Bolts
23
-
200
Flywheel Bolts - 3.7L
81
60
-
Flywheel Bolts - 2.5L
Diesel
45
33
-
Master Cylinder Nuts
38
28
-
Slave Cylinder Nuts
23
17
-
Pedal Bracket Nuts
39
29
-
6 - 6
CLUTCH
KJ
DISC-CLUTCH
REMOVAL
1. Remove transmission.
2. Mark position of pressure plate (1) on flywheel with
paint or a scriber for assembly reference, if clutch
is not being replaced.
3. Loosen pressure plate bolts evenly and in rotation
to relieve spring tension and avoid warping the
plate.
4. Remove pressure plate bolts and pressure plate
and disc.
INSTALLATION
GAS ENGINES
1. Lightly scuff sand flywheel face with 180 grit emery
cloth, then clean with a wax and grease remover.
2. Lubricate pilot bearing with Mopar high temperature
bearing grease or equivalent.
3. Check runout and operation of new clutch disc.
NOTE: Disc must slide freely on transmission
input shaft splines.
4. With the disc on the input shaft, check face runout
with dial indicator. Check runout at disc hub 6 mm
(1/4 in.) from outer edge of facing. Obtain another
clutch disc if runout exceed 0.5 mm (0.020 in.).
5. Position clutch disc on flywheel with side marked
flywheel against the flywheel.
NOTE: If not marked, the flat side of disc hub goes
towards the flywheel.
6. Insert clutch alignment tool (3) through the clutch disc and into the pilot bearing.
7. Position clutch pressure plate (2) over disc and on the flywheel (1).
8. Install pressure plate bolts finger tight.
CAUTION: Use only the factory bolts to mount the pressure plate. The bolts must be the correct size. If
bolts are too short, there isn’t enough thread engagement, if too long bolts interfere with the Dual Mass
Flywheel.
9. Tighten pressure plate bolts evenly and in rotation a few threads at a time.
CAUTION: The bolts must be tightened evenly and to specified torque. Failure to follow these instructions
will distort the pressure plate.
KJ
CLUTCH
6 - 7
10. Tighten pressure plate bolts 50 N·m (37 ft. lbs.).
11. Apply light coat of Mopar high temperature bearing grease or equivalent to clutch disc hub and splines of trans-
mission input shaft.
CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc.
12. Install transmission.
DIESEL ENGINE
1. Lightly scuff sand flywheel face with 180 grit emery
cloth, then clean with a wax and grease remover.
2. Lubricate pilot bearing with Mopar high temperature
bearing grease or equivalent.
3. Check runout and operation of new clutch disc.
NOTE: Disc must slide freely on transmission
input shaft splines.
4. With the disc on the input shaft, check face runout
with dial indicator. Check runout at disc hub 6 mm
(1/4 in.) from outer edge of facing. Obtain another
clutch disc if runout exceed 0.5 mm (0.020 in.).
5. Position clutch disc on flywheel with side marked
flywheel side (1) against the flywheel. If not
marked, the flat side of disc hub goes towards the
flywheel.
6. Insert clutch alignment tool (3) through the clutch
disc and into the pilot bearing.
7. Position clutch pressure plate (2) over disc and on
the flywheel (1).
6 - 8
CLUTCH
KJ
8. Install pressure plate bolts (1) finger tight.
9. Tighten pressure plate bolts evenly and in rotation
a few threads at a time.
CAUTION: The bolts must be tightened evenly and
to specified torque. Failure to follow these instruc-
tion will distort the pressure plate.
10. Tighten pressure plate bolts to 54 N·m (40 ft.
lbs.).
11. Apply light coat of Mopar
T
high temperature bear-
ing grease or equivalent to clutch disc hub and
splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. Fail-
ure to follow these instruction will contamination
of disc.
12. Install transmission.
KJ
CLUTCH
6 - 9
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