Clutch/Flywheel question

[Glenn Humbert]

This is my first post...
I have an 03 Sport (3.7L) manual transmission (because it is practically a religion for me) - changing the clutch became an adventure because the pilot bearing disintegrated and I had a difficult time getting the remnant of the outer race out... anyway, that problem is solved.

I haven't done a lot of clutch changes so I haven't seen too many flywheels, my current one has some hot spots and over all doesn't inspire (great) confidence. Normally, I'd think of just replacing it, since usually Jeep parts are not terribly expensive - what an eye opener for this particular part - there are zero to be found and of course countless aggravating search results pointing out the abundance of dual mass flywheels for the 2.5.

My question - if you bough the entire clutch package for a later 3.7L with the dual mass flywheel, is there any reason this wouldn't just work?

or,

Is there a secret stash of 02-04 3.7L flywheels somewhere that I missed.

Bums me out, fixed many other minor things (including re-wrap almost the entire wiring loom) while I have all apart... New parts all over the place.

 

[Billwill]

I do not know about later models with the dual mass flywheel.

However I hope you are aware that your flywheel has a curve on it to match the curve of the clutch plate.

So you need to be sure that you purchase a clutch plate that has this curve and the flywheel must not be machined flat...only small scuffs can be removed with fine Emory Cloth.

The 2003 Jeep KJ Service Manual has a good description of how to replace the clutch...here is the Service Manual link if you do not already have it:

www.colorado4wheel.com/manuals/Jeep/KJ/

 

[Glenn Humbert]

Thanks, I am painfully aware of this. Thanks for the link, the service manual is invaluable.

I am going to clean this one up and give it a try - if I have a problem the only replacement option is the new kit - that's why I asked, I don't want to take the ebay sellers word for it.

 

[adamkrz]

I bought a used flywheel in case I needed one when I replaced my clutch, I could not find a new one anywhere ( 5 years ago ) but used my old one anyway which was in good shape - I just scuffed it up with sandpaper.

I still have a used one from an 04 and I swear it's flat. ???

Another part not available will be the fuel pump only for the 02,03 and 04's which sits horizontal in the tank and separate from the flange which can develop small cracks then give a small evap leak code that will drive you crazy,

 

[Glenn Humbert]

Well, they do state the runout is 0.003", which is fairly slight - I bet you can truly detect it with a dial gauge. I have a 93 XJ and I can't even remember if I cleaned up the flywheel when I did the clutch, it was a piece of cake - my experience with XJ led me to KJ, what I am discovering is Jeep was afraid to just make a damn Jeep... LOL.

Either that or they could have just used the stupid dual mass from the get go.

I think I may have found a junkyard 2wd with a stick, if so I am going to do the same - I am going to give my original a try and go get the other one for backup. It seems a shame to have to woarry about not being able to change the cllutch, because I intend to put at least another 100k on this.

I would still love to know if the ebay kit with the dual mass will work like they claim - if I had suspected anything like this I might have just bought that from the start.

I really like my KJ otherwise - I have a Patriot for a family car, but I cracked the windshield taking it fishing - body flex from a rough road, that was the inspiration to find a KJ - I must have a stick, I am allergic to auto...

Thanks for the response.

 

[Billwill]

I have a 5 speed manual box on my 2002 Export 2.5 CRD which I wanted...the auto box came out about a year later.

If I had to get a newer Jeep now I would prefer an automatic...getting a bit old now!

Modern automatics are a lot smoother than the old ones but looking at all the posts these auto boxes seem to be a bit finicky!

I have replaced the clutch on my 2002 CRD about 3 times now over 18 years of ownership...but only 190,000 kms!

 

[adamkrz]

I really beat up my clutch teaching my kids to drive, towing a small camper and some moderate off roading and after 150k it was still in great shape - throw out bearing was making some noise - flywheel was in real nice shape.

Probably correct about the small run out not detectable with a straightedge though, At least I know I have a spare..

 

[Glenn Humbert]

Wow Billwill - I am a little jealous of your location... I am a bit of an animal nut.

I don't care how great autos may be now, I can't stand driving them, LOL.
I had a Nissan Frontier with the supercharger that was auto - I lasted three months and had to trade it for a stick.

 

[Billwill]

Wow Billwill - I am a little jealous of your location... I am a bit of an animal nut.

Yeah I retired early at age 55 so I could move to White River Mbombela Mpumalanga....try saying that after a few drinks....warm weather and 35 minutes to the Kruger National Park!

At first I had a fantastic large house I had built on a large stand with a fantastic view but have had to downsize now.

The Kruger Park has been closed due to Covid 19 and the animals started to take over....lying all over the tarmac roads for the heat!

The Park is now open to limited visitors but bookings have to be made in advance and no overnight stays...I cannot wait for it to open again...my dark green KJ blends in nicely!

 

[Glenn Humbert]

Update - finally reassembled and the old flywheel works great. I feel like a learned a little about how to judge them, so anyone seeing this thread in the future, if you want a second opinion on your, post a pic and I will try to reply.