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Jeep Grand Cherokee 1999-2004 WJ WG Factory Workshop Service Repair Manual download

Tools & supplies (common to both procedures)
- Safety: safety glasses, nitrile gloves, fire extinguisher nearby
- Basic hand tools: 1/4" & 3/8" ratchets, metric sockets 8–15 mm, short/extension swivel
- Torque wrench (0–50 ft·lb range)
- Flat & Phillips screwdrivers, pick set
- Needle-nose pliers, snap-ring/circlip pliers (if needed)
- Flare‑nut (line) wrenches set (8, 10, 11 mm typical)
- Small adjustable wrench
- Electrical contact cleaner and dielectric grease
- Clean rags, drip pan, disposable bottle for brake/clutch fluid
- DOT 3/DOT 4 brake fluid (OEM spec)
- Clear tubing and one-way bleed valve or bench/pressure bleeder OR two-person bleed setup
- Replacement part: clutch pressure switch/sensor (OEM or aftermarket exact match) and any supplied O‑ring/seal
- Optional: masking tape and marker to label connectors, plastic trim tools

Safety precautions (read first)
- Work on level ground, parking brake on, wheels chocked.
- Disconnect battery negative if working on electrical connectors near ECM or to prevent accidental cranking during work.
- Avoid getting brake/clutch fluid on painted surfaces (it will damage paint). Immediately rinse with water if spilled.
- Wear eye protection when opening hydraulic system or bleeding.
- If vehicle must be raised, use jack stands—never rely on a jack alone.

Which sensor? Two common items referred to as “clutch sensor” on WJ:
A) Hydraulic clutch pressure switch/sensor on the master cylinder or hydraulic line (engine bay).
B) Clutch pedal switch (clutch position/safety switch) under the dash.

I will give step‑by‑step for both. Follow only the section that applies to your vehicle.

A) Clutch hydraulic pressure switch — engine bay replacement
Typical symptoms: no-crank interlock issue, cruise disablement, or ECU/clutch faults; sometimes a fluid leak from sensor area.

1) Locate sensor
- Open hood. Clutch master cylinder is on driver side firewall near brake master cylinder. Pressure switch usually screws into the master cylinder body or a hydraulic line fitting close to it. It’s a small threaded sensor with a 2-pin (or 3-pin) electrical connector.

2) Prepare vehicle & drain small amount of fluid
- Place drip pan under master cylinder.
- Remove any engine covers blocking access.
- Clean the area around the sensor thoroughly to prevent contamination entering the system when sensor is removed.

3) Disconnect battery negative (recommended)
- Prevents shorts while disconnecting sensor. If you prefer, at minimum disconnect the sensor connector.

4) Disconnect electrical connector
- Depress the tab, pull connector straight back. Use a flat screwdriver to lift the locking tab if stuck. Clean contacts with electrical cleaner if corroded.

5) Remove sensor
- Use the correct size shallow socket or open-end wrench on the sensor body (do NOT use pliers on the connector plastic). If sensor hex is small, a 16 mm or smaller deep socket may be needed. Use a flare‑nut wrench for hydraulic fittings if it’s a line union. Hold surrounding components to avoid stress.
- Unscrew sensor slowly. Catch escaping fluid in the drip pan and immediately cap the master cylinder opening with clean rag to reduce contamination and air entry.

6) Inspect O‑ring/seal and mounting port
- Remove old O‑ring; clean seat thoroughly. If new sensor includes an O‑ring, use it. Do NOT reuse old O‑ring.

7) Install new sensor
- Lightly lubricate new O‑ring with fresh brake/clutch fluid and seat it on sensor. Thread sensor by hand to avoid cross-threading.
- Tighten to snug. Typical small switch torque is low — approximately 8–15 ft·lb (10–20 N·m). If you have factory torque spec, use it. Over‑torquing will shear plastic or distort threads.

8) Reconnect electrical connector
- Apply small amount of dielectric grease to connector pins, seat connector until locked.

9) Refill & bleed clutch hydraulic system
- Top master cylinder reservoir to the “MAX” with DOT 3/4 fluid.
- Because system was opened, bleed clutch: either two-person (pump pedal, hold, open bleeder nipple, close, repeat) or use one‑way bleeding hose or pressure bleeder. Use clear hose on slave cylinder bleed nipple; open 1/4 turn during bleed cycles until no air and pedal feels firm.
- Typical bleeder nut size ~8–10 mm; use a wrench that fits snugly to avoid rounding.

10) Check for leaks & test operation
- With engine off, depress clutch several times and check for leaks around sensor. Start engine (with vehicle in neutral and parking brake set) and check sensor circuits and operations (starter interlock, cruise, DTCs).
- If codes present, clear with scan tool and confirm they do not return.

Common pitfalls (hydraulic)
- Cross-threading the sensor — always start by hand.
- Over‑torquing plastic sensor/housing — use torque wrench and low torque.
- Reusing O‑ring — replace it.
- Not bleeding properly — soft pedal or incomplete clutch disengagement.
- Using wrong fluid or contaminating paint.

B) Clutch pedal position / safety switch — under dash replacement
Typical symptoms: starter won’t crank unless pedal pressed, cruise control faults, or no response to clutch pedal switch.

1) Locate switch
- Under driver side dash, near top of clutch pedal arm. Switch is small, typically with a plunger or threaded body and an electrical connector.

2) Access
- Remove lower dash panel/trim with screwdriver or trim tools for access. You may need to recline the seat to get comfortable access.

3) Safety & prepare
- Disconnect negative battery terminal or at least the sensor connector.
- Label connector if multiple similar connectors are present.

4) Adjust/check switch position before removal
- Note switch’s travel/actuation position. Some switches are adjustable (threaded) to set engagement. Note or mark the position relative to the pedal arm with a marker or scribe for reinstallation.

5) Remove connector and switch
- Depress connector tab and disconnect. Remove retaining clip or unscrew the switch (some have retaining nut or push‑in retainer). Use pliers or small wrench if needed.

6) Install new switch
- If threaded, screw in to same depth as old one or set so plunger lightly contacts pedal when released (pedal should close switch; check service manual for exact free/play).
- Torque lightly or secure clip.

7) Adjust switch & test
- Reconnect connector and battery. Verify that switch actuates: with key ON, test that starter interlock function is as expected (do not crank with vehicle in gear). Use an auxiliary test light or DVOM to check continuity when pedal is depressed/released.
- If adjustable, fine tune so that switch actuates just before pedal is fully depressed/allowed — this ensures safe starter interlock and cruise control behavior.

8) Reassemble trim and final test
- Replace trim panel. Test driving functions: starting, cruise enable, and any related fault codes.

Common pitfalls (pedal switch)
- Misadjusting so switch is always closed or never closes — leads to no-crank or unexpected starter engagement.
- Forcing connector and breaking tab—use small screwdriver to lift clip if needed.
- Not verifying function before reinstalling trim.

How to use specific tools in these tasks
- Flare‑nut wrench: place over hydraulic fitting to fully seat on flats; turn slowly to avoid rounding. Used when loosening any union nut or hydraulic line.
- Torque wrench: set to low torque (see spec), tighten sensor until it clicks at set torque. For small sensors, use a 1/4" drive torque wrench for better control.
- Clear tubing + catch bottle: push clear tube onto slave bleeder nipple, route into a graduated bottle partially filled with fluid to avoid drawing air back.
- Pick/trim tools: gently pry electrical connector locking tangs; protect plastic housings.
- Bench/pressure bleeder: use recommended pressure (PSI per tool) and follow tool instructions. Never exceed manufacturer pressure.

Replacement parts & consumables
- Correct clutch pressure switch/sensor (OEM part recommended) — ensure correct connector type and thread/O‑ring.
- O‑ring/seal (if not supplied)
- DOT 3 or DOT 4 brake/clutch fluid (as specified by Jeep)
- New retaining clips or switch if damaged

Final verification
- Check for leaks after 24 hours of operation.
- Confirm clutch pedal feel is firm and engagement point matches previous behavior.
- Use an OBDII scanner to confirm no persistent clutch/ECU codes. Clear if necessary.

Troubleshooting tips
- If pedal remains soft after bleeding, recheck for air entry, leaking slave or master cylinder, or failed master/slave cylinder.
- If starter still doesn't engage after pedal switch replacement, verify wiring back to starter relay and check ground and fuse circuits.
- If sensor connector has corrosion, replace connector or repair pigtail.

End.
rteeqp73

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