Download Jeep Cherokee KJ 2002-2007 Workshop Repair Service Manual –

Replacing the clutch plate on a Jeep Cherokee KJ (2002-2007 models) is a task that requires mechanical skills, tools, and safety precautions. Find additional details in the downloadable manual……

below is a detailed step-by-step guide to help you through the process, including descriptions of each component involved.

### Tools and Materials Needed:

1. **Tools:**
– Jack and jack stands (or a hydraulic lift)
– Socket set (metric)
– Wrench set
– Torque wrench
– Screwdrivers (flathead and Phillips)
– Pliers
– Clutch alignment tool
– Flywheel removal tool (if necessary)
– Brake cleaner
– Shop rags
– Bungee cords or rope (to support the transmission)

2. **Materials:**
– New clutch kit (includes clutch disc, pressure plate, and release bearing)
– New pilot bearing (if applicable)
– Transmission fluid (if needed)
– Anti-seize lubricant (for bolts)
– Thread locker (if recommended for specific bolts)

### Safety Precautions:

– Always wear safety glasses and gloves.
– Work in a well-ventilated area.
– Ensure the vehicle is on a flat surface.
– Use jack stands to support the vehicle securely.
– Disconnect the battery to prevent electrical issues.

### Step-by-Step Guide:

#### 1. Preparation:

1. **Disconnect the Battery:**
– Remove the negative terminal from the battery to prevent any electrical shorts.

2. **Lift the Vehicle:**
– Use a jack to lift the vehicle and support it with jack stands. Ensure it’s stable before working underneath.

#### 2. Remove the Transmission:

1. **Remove the Exhaust:**
– Unbolt the exhaust system from the exhaust manifold and any hangers that may obstruct the transmission removal. Remove the exhaust pipe leading to the muffler if necessary.

2. **Remove the Driveshaft:**
– Depending on your model (2WD or 4WD), unbolt the driveshaft from the rear axle and the transfer case (if 4WD). Mark the position of the driveshaft for reinstallation.

3. **Disconnect the Linkage:**
– Remove the shift linkage from the transmission. This usually involves unbolting a few bolts or clips.

4. **Unplug Electrical Connectors:**
– Disconnect any electrical connectors attached to the transmission, including the speed sensor and any other sensors.

5. **Remove the Transmission Mount:**
– Unbolt the transmission mount from the crossmember and the transmission itself. Support the transmission with a jack or a transmission jack.

6. **Unbolt the Transmission:**
– Remove the bolts securing the transmission to the engine bell housing. There are usually several bolts located around the perimeter.

7. **Separate the Transmission:**
– Carefully pull the transmission away from the engine. You may need to wiggle it slightly to free it from the input shaft.

#### 3. Access the Clutch Assembly:

1. **Remove the Flywheel (if necessary):**
– If you need to replace the flywheel, remove it by unbolting it from the crankshaft. Note that this is optional if the flywheel is in good condition.

2. **Inspect and Replace the Pilot Bearing:**
– Remove the old pilot bearing from the crankshaft. You can use a bearing puller for this. Install the new pilot bearing by carefully tapping it in place.

#### 4. Replace the Clutch Components:

1. **Remove the Pressure Plate:**
– Unbolt the pressure plate from the flywheel. Carefully lift the pressure plate off the clutch disc.

2. **Remove the Clutch Disc:**
– Slide the old clutch disc off the input shaft and remove it from the assembly.

3. **Install the New Clutch Disc:**
– Place the new clutch disc onto the input shaft, ensuring it is oriented correctly (the side marked for the flywheel should face the flywheel).

4. **Install the New Pressure Plate:**
– Position the new pressure plate over the clutch disc. Use a clutch alignment tool to hold the disc in place while you install the pressure plate bolts.

5. **Torque the Pressure Plate Bolts:**
– Tighten the bolts in a crisscross pattern to ensure even pressure. Refer to your vehicle’s specifications for the correct torque settings.

#### 5. Reassemble the Transmission:

1. **Reinstall the Flywheel (if removed):**
– If you removed the flywheel, reinstall it using the correct torque specifications.

2. **Reconnect the Transmission:**
– Carefully align the transmission with the engine. You may need to rotate the input shaft slightly to help it slide into place.

3. **Bolt the Transmission:**
– reinstall all transmission bolts to secure it to the engine.

4. **Reconnect the Transmission Mount:**
– Reattach the transmission mount to the crossmember download Jeep Cherokee KJ workshop manual and the transmission.

5. **Reconnect the Linkage and Electrical Connectors:**
– Reattach the shift linkage and any electrical connectors you previously disconnected.

6. **Reinstall the Driveshaft:**
– Reattach the driveshaft to the rear axle and the transfer case (if applicable).

7. **Reinstall the Exhaust:**
– Reconnect the exhaust system, ensuring all bolts and hangers are secure.

#### 6. Final Steps:

1. **Recheck Everything:**
– Double-check all connections, bolts, and components for proper installation.

2. **Reconnect the Battery:**
– Reattach the negative battery terminal.

3. **Lower the Vehicle:**
– Carefully remove the jack stands and lower the vehicle to the ground.

4. **Test Drive:**
– Start the vehicle and take it for a test drive to ensure the clutch functions properly.

### Conclusion:

Replacing the clutch plate on a Jeep Cherokee KJ can be a challenging task, but following these detailed steps can help you do it properly. Always refer to your vehicle’s service manual for specific torque specifications and additional instructions. If you are not confident in performing this task, consider seeking assistance from a professional mechanic.
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