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CLUTCH

TABLE OF CONTENTS
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DESCRIPTION AND OPERATION
MODULAR CLUTCH ASSEMBLY. . . . . . . . . . . . . . 1
CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CLUTCH INTERLOCK/UPSTOP SWITCH. . . . . . . . 1
DIAGNOSIS AND TESTING
CLUTCH SYSTEM DIAGNOSIS. . . . . . . . . . . . . . . 2
DRIVE PLATE MISALIGNMENT . . . . . . . . . . . . . . 5
CLUTCH CHATTER COMPLAINTS . . . . . . . . . . . . 5
CLASH–INTO–REVERSE COMPLAINTS . . . . . . . . 5
CLUTCH INTERLOCK/UPSTOP SWITCH. . . . . . . . 5
REMOVAL AND INSTALLATION
CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLUTCH INTERLOCK/UPSTOP SWITCH. . . . . . . . 8
MODULAR CLUTCH ASSEMBLY. . . . . . . . . . . . . . 8
RELEASE BEARING AND FORK . . . . . . . . . . . . . 12
CLEANING AND INSPECTION
CLUTCH CONTAMINATION. . . . . . . . . . . . . . . . . 12
CLEANING PRECAUTIONS . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION AND OPERATION
MODULAR CLUTCH ASSEMBLY
Al l 2.0L SOHC engi nes equi pped wi th the A578
5-speed transaxl e use a modul ar cl utch assembl y
(Fi g. 1). The transaxl e must be removed to gai n
access to and repl ace the modul ar cl utch, dri ve pl ate,
and/or cl utch rel ease beari ng and l ever.
The modul ar cl utch assembl y used i n thi s vehi cl e
consi sts of a si ngl e, dry-type cl utch di sc, a di aphragm
styl e cl utch cover, and an i ntegrated fl ywheel . The
cl utch cover i s ri veted to the fl ywheel , contai ni ng the
cl utch di sc wi thi n. The modul ar cl utch can onl y be
servi ced as an assembl y.
The cl utch di sc has cushi on spri ngs ri veted to the
di sc hub assembl y. The cl utch di sc faci ngs are ri veted
to the cushi on spri ngs. The faci ngs are made from a
non-asbestos materi al .
The cl utch cover pressure pl ate assembl y i s a di a-
phragm type uni t wi th a one-pi ece di aphragm spri ng
wi th mul ti pl e rel ease fi ngers. The pressure pl ate
rel ease fi ngers are preset duri ng manufacture and
are not adjustabl e.
CLUTCH CABLE
The cl utch cabl e assembl y (Fi g. 2) carri es the
movement of the cl utch pedal to the cl utch rel ease
beari ng. The cabl e i s desi gned to mai ntai n tensi on
agai nst the cl utch fork, or l ever, and has a bui l t i n
sel f-adjusti ng mechani sm, whi ch compensates for
cl utch di sc wear.
CLUTCH INTERLOCK/UPSTOP SWITCH
DESCRIPTION
The cl utch i nterl ock/upstop swi tch i s an assembl y
consi sti ng of two swi tches: an engi ne starter i nhi bi t
swi tch (i nterl ock) and a cl utch pedal upstop swi tch
(Fi g. 3). The swi tch assembl y i s l ocated i n the cl utch/
brake pedal bracket assembl y (Fi g. 4), each swi tch
bei ng fastened by four pl asti c wi ng tabs.
OPERATION
Clutch Interlock Switch
The cl utch i nterl ock swi tch prevents engi ne starter
operati on and i nadvertent vehi cl e movement wi th the
cl utch engaged and the transaxl e i n gear.
Fig. 1 Modular Clutch Assembly
1 – MODULAR CLUTCH ASSEMBLY
PL CLUTCH 6 - 1
The swi tch i s open whi l e the cl utch pedal i s at
rest. When the cl utch pedal i s ful l y depressed, the
pedal bl ade contacts and cl oses the swi tch, sendi ng a
si gnal to the PCM, al l owi ng engi ne starter operati on.
The i nterl ock swi tch i s not adjustabl e.
Clutch Pedal Upstop Switch
Wi th the cl utch pedal at rest, the cl utch pedal
upstop swi tch i s cl osed, al l owi ng speed control oper-
ati on. When the cl utch pedal i s depressed, the upstop
swi tch opens and si gnal s the PCM to cancel speed
control operati on, and enter a modi fi ed engi ne cal i -
brati on schedul e to i mprove dri veabi l i ty duri ng gear-
to-gear shi fts. The upstop swi tch i s not adjustabl e.
DIAGNOSIS AND TESTING
CLUTCH SYSTEM DIAGNOSIS
Cl utch probl em di agnosi s wi l l general l y requi re a
road test to determi ne the type of faul t. Component
i nspecti on wi l l then determi ne the probl em after road
testi ng.
Dri ve the vehi cl e at normal speeds duri ng road
test. Shi ft the transaxl e through al l gear ranges and
observe cl utch acti on. I f chatter, grab, sl i p, or
i mproper rel ease i s experi enced, remove and i nspect
the cl utch components. I f the probl em i s noi se or
hard shi fti ng, further di agnosi s may be needed. The
transaxl e or other dri vel i ne components may actual l y
be at faul t.
Fig. 2 Clutch Cable Assembly
1 – ADJUSTER MECHANISM
2 – CLUTCH CABLE
Fig. 3 Clutch Interlock/Upstop Switch
1 – UPSTOP SWITCH
2 – INTERLOCK SWITCH
3 – CONNECTOR
Fig. 4 Clutch/Brake Pedal Bracket Assembly
1 – UPSTOP SWITCH
2 – CLUTCH PEDAL
3 – INTERLOCK SWITCH
4 – CONNECTOR
6 - 2 CLUTCH PL
DESCRIPTION AND OPERATION (Continued)
SERVICE DIAGNOSIS—CLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC
FACING COVERED
WITH OIL OR
GREASE
Oil leak at engine rear main or transaxle
input shaft seal
Correct leak and replace modular clutch
assembly
Too much grease applied to splines of disc
and input shaft
Apply lighter coating of grease to splines
NO FAULT FOUND
WITH CLUTCH
COMPONENTS
Problem actually related to suspension or
driveline component
Further diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL
ENGAGEMENT OF
CLUTCH DISC
Clutch cover, spring, or release fingers
bent, distorted (rough handling, improper
assembly)
Replace modular clutch assembly
Clutch disc damaged or distorted Replace modular clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for damage.
Correct as necessary.
SERVICE DIAGNOSIS—CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING
WORN OUT
Normal wear. Replace modular clutch assembly.
Driver frequently rides (slips) clutch, results
in rapid wear overheating.
Replace modular clutch assembly
Insufficient clutch cover diaphragm spring
tension
Replace modular clutch assembly
CLUTCH DISC
FACING
CONTAMINATED
WITH OIL OR
GREASE
Leak at rear main oil seal or transaxle input
shaft seal
Replace leaking seals. Replace modular
clutch assembly.
Excessive amount of grease applied to
input shaft splines
Apply less grease to input shaft. Replace
modular clutch assembly
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS
RUNNING
PARTIALLY
DISENGAGED
Release bearing sticking or binding, does
not return to normal running position.
Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.
Cable self-adjuster mechanism sticking or
binding causing high preload
Verify that self-adjuster is free to move
PL CLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC
FACINGS HAVE
FRACTURED INTO
SMALL PIECES
Driver performs a 5-1 downshift at vehicle
speed in excess of 60 miles per hour
Alert driver to problem cause. Replace
modular clutch assembly.
Leak at rear main or transaxle input shaft
seal
Replace modular clutch assembly. Replace
seal.
Excessive heat from slippage Replace modular clutch assembly
SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC
BINDS ON INPUT
SHAFT SPLINES
Clutch disc hub splines damaged during
installation
Clean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly
and/or input shaft if splines are severely
damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on splines of
input shaft and disc
Clean input shaft splines and disc splines,
then lube
CLUTCH DISC
RUSTED TO
FLYWHEEL
AND/OR
PRESSURE PLATE
Occurs in vehicles stored or not driven for
extended period of time. Also occurs after
steam cleaning if vehicle is not used for
extended period.
Replace modular clutch assembly
CLUTCH WILL NOT
DISENGAGE
PROPERLY
Disc bent, distorted during transaxle
installation
Replace modular clutch assembly
Clutch cover diaphragm spring damaged
during transaxle installation
Replace modular clutch assembly
Release fork bent, loose, or damaged Replace fork if worn or damaged
Clutch cable binding or routed incorrectly Check and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable slack
Pull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
SERVICE DIAGNOSIS–CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL
MAKES REPEATED
“POP” NOISE IN
THE FIRST INCH
OF TRAVEL
Self-adjusting mechanism in cable defective Replace clutch cable
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO
FLOOR
Pedal bushings worn out or inadequate
lubrication
Replace or lubricate bushings
Clutch pedal return spring worn out Lubricate or replace return spring
Clutch release lever pivot stud has
inadequate lubrication
Lubricate or replace clutch release lever
6 - 4 CLUTCH PL
DIAGNOSIS AND TESTING (Continued)
DRIVE PLATE MISALIGNMENT
Common causes of mi sal i gnment are:
• Heat warpi ng
• Mounti ng dri ve pl ate on a di rty crankshaft
fl ange
• I ncorrect bol t ti ghteni ng
• I mproper seati ng on the crankshaft shoul der
• Loose crankshaft bol ts
Cl ean the crankshaft fl ange before mounti ng the
dri ve pl ate. Di rt and grease on the fl ange surface
may mi sal i gn the fl ywheel , causi ng excessi ve runout.
Use new bol ts when mounti ng dri ve pl ate to crank-
shaft. Ti ghten dri ve pl ate bol ts to speci fi ed torque
onl y. Over-ti ghteni ng can di stort the dri ve pl ate hub
causi ng excessi ve runout.
CLUTCH CHATTER COMPLAINTS
For al l cl utch chatter compl ai nts, do the fol l owi ng:
(1) Check for l oose, mi sal i gned, or broken engi ne
and transmi ssi on mounts. I f present, they shoul d be
corrected at thi s ti me. Test vehi cl e for chatter. I f
chatter i s gone, there i s no need to go any further. I f
chatter persi sts:
(2) Check to see i f cl utch cabl e routi ng i s correct
and operates smoothl y.
(3) Check for l oose connecti ons i n dri ve trai n. Cor-
rect any probl ems and determi ne i f cl utch chatter
compl ai nts have been sati sfi ed. I f not:
(4) Remove transaxl e. See Group 21, Manual Tran-
saxl e for procedure.
(5) Check to see i f the rel ease beari ng i s sti cky or
bi ndi ng. Repl ace beari ng, i f needed.
(6) Check l i nkage for excessi ve wear on the pi vot
stud and fork fi ngers. Repl ace al l worn parts.
(7) Check cl utch assembl y for contami nati on (di rt,
oi l ). Repl ace cl utch assembl y, i f requi red.
(8) Check to see i f the cl utch di sc hub spl i nes are
damaged. Repl ace wi th new cl utch assembl y, i f nec-
essary.
(9) Check i nput shaft spl i nes for damage. Repl ace,
i f necessary.
(10) Check for uneven wear on cl utch fi ngers.
(11) Check for broken cl utch cover di aphragm
spri ng fi ngers. Repl ace wi th new cl utch assembl y, i f
necessary.
CLASH–INTO–REVERSE COMPLAINTS
Certai n NV T350 (A-578) manual transaxl es are
equi pped wi th a reverse brake. I t prevents cl ash
when shi fti ng i nto reverse, but onl y i f the vehi cl e i s
not movi ng. See Group 21, Transaxl e for further
di agnosi s.
(1) Depress cl utch pedal to fl oor and hol d. After
three seconds, shi ft to reverse. I f cl ash i s present,
cl utch has excessi ve spi n ti me, and the reverse brake
may not be functi oni ng.
(2) Remove transaxl e. See Group 21, Manual Tran-
saxl e for procedure.
(3) Check the i nput shaft spl i ne, cl utch di sc
spl i nes, and rel ease beari ng for dry rust. I f present,
cl ean rust off and appl y a l i ght coat of beari ng grease
to the i nput shaft spl i nes. Appl y grease on the i nput
shaft spl i nes onl y where the cl utch di sc sl i des. Veri fy
that the cl utch di sc sl i des freel y al ong the i nput shaft
spl i ne.
(4) Check to see i f the cl utch di sc hub spl i nes are
damaged, and repl ace wi th new cl utch assembl y i f
requi red.
(5) Check the i nput shaft for damaged spl i nes.
Repl ace as necessary.
(6) Check for broken cl utch cover di aphragm
spri ng fi ngers.
(7) I nstal l cl utch assembl y and transaxl e.
CLUTCH INTERLOCK/UPSTOP SWITCH
The cl utch i nterl ock/upstop swi tch i s an assembl y
consi sti ng of two swi tches: an engi ne starter i nhi bi t
swi tch (cl utch i nterl ock) and a cl utch pedal upstop
swi tch (Fi g. 5). The swi tch assembl y i s l ocated i n the
cl utch/brake pedal bracket assembl y (Fi g. 6), each
swi tch bei ng fastened by four pl asti c wi ng tabs.
CLUTCH INTERLOCK SWITCH
Mechanical Test
(1) Wi th the park brake set and the transaxl e IN
NEUTRAL, turn the i gni ti on key to the start posi -
ti on. The engi ne starter shoul d not crank wi th the
cl utch pedal at rest (not depressed). I f the starter
cranks, proceed to the el ectri cal test to determi ne
whether the swi tch i s defecti ve or the ci rcui t i s
shorted. I f the vehi cl e does not crank, proceed to the
next step.
(2) Wi th the park brake set and the transaxl e IN
NEUTRAL, ful l y depress the cl utch pedal and turn
Fig. 5 Clutch Interlock/Upstop Switch
1 – UPSTOP SWITCH
2 – INTERLOCK SWITCH
3 – CONNECTOR
PL CLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)
the i gni ti on key to the start posi ti on. The engi ne
starter shoul d crank. I f the starter does not crank,
vi sual l y i nspect the cl utch pedal for obstructi ons
(fl oor mat, etc.). Al so make sure the cl utch pedal
bl ade contacts and ful l y
Electrical Test
(1) Move i gni ti on key to the “OFF/LOCK” posi ti on
and remove key.
(2) Set park brake.
(3) Di sconnect the cl utch i nterl ock/upstop swi tch
connector.
(4) Usi ng an ohmmeter, check for conti nui ty
between termi nal s 2 & 3 wi th the i nterl ock swi tch
not depressed (cl utch pedal at rest). There shoul d be
no conti nui ty between the termi nal s (open ci rcui t).
(5) Ful l y depress the cl utch pedal to cl ose the
swi tch at l east 1.25 mm (0.050 i n.). The ohmmeter
shoul d show conti nui ty (0 ohms).
(6) I f ohmmeter readi ngs do not fal l wi thi n these
ranges, the swi tch assembl y i s defecti ve and shoul d
be repl aced. I f the swi tch tests ok, wi ri ng i s defecti ve.
Refer to Group 8W, Wi ri ng Di agrams and repai r
defecti ve wi ri ng.
UPSTOP SWITCH
Mechanical Test
(1) Rai se vehi cl e on hoi st.
(2) Start engi ne and operate speed control to mai n-
tai n speed.
(3) Depress cl utch pedal at l east 33 mm (1.30 i n.).
Speed control operati on shoul d termi nate. I f speed
control does not termi nate, the upstop swi tch i s
defecti ve or the rel ated wi ri ng i s shorted. Proceed to
the upstop swi tch el ectri cal test.
Electrical Test
(1) Move i gni ti on key to the “OFF/LOCK” posi ti on
and remove key.
(2) Set park brake.
(3) Di sconnect the cl utch i nterl ock/upstop swi tch
connector.
(4) Usi ng an ohmmeter, check for conti nui ty
between termi nal s 1 & 2 wi th the upstop swi tch
depressed (cl utch pedal at rest). The ohmmeter
shoul d show conti nui ty (0 ohms).
(5) Depress the cl utch pedal at l east 33 mm (1.30
i n.) check for conti nui ty between termi nal s 1 & 2.
There shoul d be no conti nui ty between the termi nal s
(open ci rcui t).
(6) I f ohmmeter readi ngs do not fal l wi thi n these
ranges, the swi tch assembl y i s defecti ve and shoul d
be repl aced. I f the swi tch tests ok, wi ri ng i s defecti ve.
Refer to Group 8W, Wi ri ng Di agrams and repai r
defecti ve wi ri ng.
Fig. 6 Clutch/Brake Pedal Bracket Assembly
1 – UPSTOP SWITCH
2 – CLUTCH PEDAL
3 – INTERLOCK SWITCH
4 – CONNECTOR
6 - 6 CLUTCH PL
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSIS–CLUTCH INTERLOCK/UPSTOP SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE STARTER
WON’T CRANK
WHEN CLUTCH
PEDAL IS
PRESSED TO THE
FLOOR
Clutch interlock switch does not have
continuity when plunger is depressed 1.25
mm (1.30 in.)
Defective switch or open wiring circuit.
Replace switch if necessary.
Interlock switch plunger is not depressed
when clutch pedal is pushed to the floor
Floor mat interferes with clutch pedal
movement or clutch pedal bracket is bent.
Problem is related to other components in
the starting circuit.
Check other components in the starting
circuit. Refer to Battery/Starting/Charging
System in Group 8.
SPEED CONTROL
DOES NOT
TERMINATE WHEN
CLUTCH PEDAL IS
DEPRESSED BY AT
LEAST 33 mm (1.30
in.)
Upstop switch circuit is closed when clutch
pedal is depressed, or harness is shorted.
Refer to Upstop Switch Electrical Test in
this group. Repair wiring or replace switch
assembly as necessary.
Other speed control system failure. Refer to Group 8H, Speed Control for
further diagnosis and testing procedures.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Di sconnect both battery cabl es.
(2) Remove battery cl amp and remove battery
from vehi cl e.
(3) Remove battery tray from mount bracket.
(4) Remove bel l housi ng cap (Fi g. 7).
(5) Di sconnect cl utch cabl e from transaxl e housi ng
and cl utch rel ease l ever as shown i n (Fi g. 7).
(6) Di sconnect the cl utch cabl e from the cl utch
pedal spacer (Fi g. 8).
NOTE: Use care when handling clutch cable
assembly. Improper handling can cause adjuster
mechanism to come apart, making re-installation
difficult.
(7) Careful l y gui de cabl e through pedal assembl y
bore and remove from vehi cl e.
INSTALLATION
(1) I nsert the cl utch pedal end of the cabl e i nto
posi ti on and connect the cabl e to the cl utch pedal
spacer as shown i n (Fi g. 8).
(2) Veri fy adjuster mechani sm functi on as fol l ows:
(a) Wi th sl i ght pressure, pul l the cl utch rel ease
l ever end of the cabl e to draw the cabl e taut.
(b) Push the cl utch cabl e housi ng toward the
dash panel (Wi th l ess than 25 l bs. of effort, the
cabl e housi ng shoul d move 30-50mm.). I f the cabl e
Fig. 7 Clutch Cable at Transaxle
1 – CLUTCH CABLE
2 – TRANSAXLE
3 – BELLHOUSING CAP
PL CLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)
housi ng does not move, i t i s i mproperl y i nstal l ed or
defecti ve.
(3) Route cabl e to the transaxl e and connect cabl e
end to the cl utch rel ease l ever and transaxl e housi ng
(Fi g. 7).
(4) I nstal l bel l housi ng cap (Fi g. 7).
(5) I nstal l and fasten battery tray.
(6) I nstal l battery and hol d-down cl amp.
(7) Connect both battery cabl es.
(8) Veri fy that the cl utch cabl e i s worki ng properl y.
CLUTCH INTERLOCK/UPSTOP SWITCH
REMOVAL
(1) Di sconnect and i sol ate battery negati ve cabl e.
(2) Remove i nstrument panel assembl y. Refer to
Group 8E, I nstrument Panel and Systems for the
proper procedure.
(3) Di sconnect the cl utch i nterl ock/upstop swi tch
connector (Fi g. 9).
NOTE: Proper switch harness routing is critical to
switch durability. Note the harness routing and
location of fasteners intended to keep wires from
contacting pedals.
(4) Remove the i nterl ock/upstop swi tch assembl y
from the brake/cl utch pedal bracket assembl y by
depressi ng the four pl asti c wi ng tabs on each swi tch.
INSTALLATION
(1) I nstal l swi tches i nto the pedal bracket assem-
bl y as shown i n (Fi g. 9). Route harness as was pri or
to removal .
(2) Connect i nterl ock/upstop swi tch connector.
(3) I nstal l i nstrument panel assembl y. Refer to
Group 8E, I nstrument Panel and Systems for the
proper procedure.
(4) Connect battery negati ve cabl e.
(5) Veri fy proper swi tch operati on. Refer to
Descri pti on and Operati on i n thi s Group.
MODULAR CLUTCH ASSEMBLY
REMOVAL
(1) Rai se hood.
(2) Di sconnect and i sol ate both battery cabl es,
remove battery hol d down cl amp and bol t, and
remove battery.
(3) Remove ai r cl eaner/throttl e body assy. (Fi g. 10)
as fol l ows:
(a) Di sconnect proporti onal purge sol enoi d (PPS)
and crankcase vent hose from throttl e body.
(b) Di sconnect the Throttl e Posi ti on Sensor
(TPS) and I dl e Ai r Control (I AC) connectors.
(c) Di sconnect throttl e body ai r duct at i ntake
mani fol d.
Fig. 8 Clutch Cable at Brake/Clutch Pedal Assembly
1 – SNAP RING
2 – CLUTCH PEDAL SPACER
3 – CLUTCH PEDAL
4 – CLUTCH CABLE
Fig. 9 Interlock and Upstop Switch Mounting
Locations
1 – UPSTOP SWITCH
2 – CLUTCH PEDAL
3 – INTERLOCK SWITCH
4 – CONNECTOR
6 - 8 CLUTCH PL
REMOVAL AND INSTALLATION (Continued)
(d) Remove mounti ng bol t and nut (Fi g. 10) and
parti al l y remove ai r cl eaner assembl y.
(e) Di sconnect accel erator and speed control (i f
equi pped) cabl es after the assy. i s removed from
posi ti on. Remove ai r cl eaner assembl y from vehi -
cl e.
(4) Remove battery tray from bracket.
(5) Di sconnect ground cabl e at battery tray
bracket.
(6) Di sconnect back-up l amp swi tch connector.
(7) Remove bel l housi ng cap (Fi g. 11).
(8) Di sconnect cl utch cabl e from rel ease l ever and
remove from transaxl e (Fi g. 11).
(9) Remove shi ft cabl e-to-bracket cl i ps (Fi g. 12).
(10) Di sconnect shi ft sel ector and crossover cabl e
from l evers (Fi g. 12). Remove cabl es and secure out
of the way.
(11) Di sconnect the vehi cl e speed sensor connector
(Fi g. 13).
(12) Rai se vehi cl e on hoi st.
(13) Remove transaxl e oi l drai n pl ug and drai n oi l
i nto a sui tabl e contai ner.
(14) Remove both axl e shafts. Refer to Group 3,
Di fferenti al and Dri vel i ne for the correct procedures.
(15) Remove structural col l ar (Fi g. 14).
(16) Remove the l eft engi ne-to-transaxl e l ateral
bendi ng brace (Fi g. 14).
(17) Remove bel l housi ng dust cover (Fi g. 14).
(18) Remove the ri ght engi ne-to-transaxl e l ateral
bendi ng brace (Fi g. 15).
(19) Remove starter motor (Fi g. 16).
(20) Remove dri ve pl ate-to-cl utch modul e bol ts.
(21) Support engi ne at oi l pan wi th screw jack and
wood bl ock.
(22) Remove transaxl e upper mount thru-bol t.
Gai n access to thi s bol t through the dri ver’s si de
wheel house (Fi g. 17).
(23) Careful l y l ower engi ne and transaxl e on screw
jack unti l proper removal cl earance i s obtai ned.
Fig. 10 Air Cleaner Assembly Removal/Installation
1 – AIR CLEANER ASSY.
2 – THROTTLE BODY DUCT
FWD
Fig. 11 Clutch Cable at Transaxle
1 – CLUTCH CABLE
2 – TRANSAXLE
3 – BELLHOUSING CAP
Fig. 12 Shift Cables at Transaxle
1 – SHIFT CABLES
2 – CLIPS
3 – BRACKET
PL CLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)
(24) Obtai n a hel per to assi st i n hol di ng transaxl e
whi l e removi ng transaxl e-to-engi ne mounti ng bol ts
(Fi g. 18).
(25) Remove transaxl e from vehi cl e (Fi g. 18).
(26) Remove modul ar cl utch assembl y from tran-
saxl e i nput shaft.
INSTALLATION
(1) I nspect cl utch rel ease beari ng and l ever for
excessi ve wear and repl ace as necessary.
(2) I nstal l cl utch modul e onto i nput shaft. I nstal l
transaxl e i nto posi ti on.
(3) I nstal l transaxl e-to-engi ne mounti ng bol ts (Fi g.
18) and ti ghten to 95 N·m (70 ft. l bs.) torque.
(4) Rai se engi ne and transaxl e wi th screw jack
unti l through hol e i n upper mount al i gns wi th hol e
i n mount bracket. I nstal l mount bol t and ti ghten to
108 N·m (70 ft. l bs.) torque (Fi g. 17).
(5) Remove screwjack.
(6) I nstal l NEW dri ve pl ate-to-cl utch modul e bol ts
and progressi vel y ti ghten al l bol ts i n a cri ss-cross
pattern unti l the modul ar cl utch assembl y seats
agai nst the dri ve pl ate. Fi nal torque the bol ts to 88
N·m (65 ft. l bs.) torque.
(7) I nstal l starter motor and ti ghten bol ts to 54
N·m (40 ft. l bs.) torque. Make sure to fasten ground
cabl e to upper starter bol t as shown i n (Fi g. 16).
Fig. 13 Vehicle Speed Sensor Connector
1 – CONNECTOR
2 – SENSOR
3 – O-RING
4 – SPEEDO PINION
Fig. 14 Left Lateral Bending Brace and Structural
Collar—Typical
1 – LATERAL BENDING BRACE
2 – STRUCTURAL COLLAR
3 – DUST COVER
Fig. 15 Right Lateral Bending Brace Removal/
Installation—Typical
1 – TRANSAXLE
2 – ENGINE
3 – LATERAL BENDING BRACE
6 - 10 CLUTCH PL
REMOVAL AND INSTALLATION (Continued)
(8) Connect starter el ectri cal harness and ti ghten
posi ti ve cabl e nut to 10 N·m (90 i n. l bs.) torque.
(9) I nstal l bel l housi ng dust cover (Fi g. 14).
(10) I nstal l l eft engi ne-to-transaxl e bendi ng brace
(Fi g. 14).
(11) I nstal l structural col l ar (Fi g. 14) as fol l ows:
(a) Posi ti on col l ar and i nstal l al l bol ts fi nger
ti ght.
(b) Ti ghten the col l ar-to-oi l pan bol ts to 3 N·m
(30 i n. l bs.) torque.
(c) Ti ghten the col l ar-to-transaxl e bol ts to 108
N·m (80 ft. l bs.) torque.
(d) Fi nal torque the col l ar-to-oi l pan bol ts to 54
N·m (40 ft. l bs.) torque.
(12) I nstal l the ri ght l ateral bendi ng brace and
ti ghten bol ts to 81 N·m (60 ft. l bs.) torque (Fi g. 15).
(13) I nstal l both front axl e dri veshafts. Refer to
Group 3, Di fferenti al and Dri vel i ne for the correct
procedures.
(14) Fi l l transaxl e wi th sui tabl e amount of Mopar௡
Manual Transaxl e Lubri cant (PN 04874465).
(15) Lower vehi cl e.
(16) Connect vehi cl e speed sensor connector (Fi g.
13).
(17) Connect shi ft crossover and sel ector cabl es to
shi ft l ever. I nstal l cabl es to bracket and i nstal l
retai ni ng cl i ps (Fi g. 12).
(18) Connect cl utch cabl e to fork and secure to
transaxl e (Fi g. 11).
(19) I nstal l bel l housi ng cap (Fi g. 11).
(20) Connect back-up l amp swi tch connector.
(21) Connect ground strap to transaxl e upper
mount bracket.
(22) I nstal l battery l ower tray and battery, and
ti ghten battery hol d down cl amp to secure battery.
(23) I nstal l the ai r cl eaner/throttl e body assy. as
fol l ows:
(a) Connect the accel erator and speed control (i f
equi pped) cabl es to the ai r cl eaner/throttl e body
assy.
(b) I nstal l assy i nto posi ti on, maki ng sure the
ai r cl eaner l ocati ng sl ot i s engaged to the battery
bracket tab, and ti ghten fasteners to 14 N·m (120
i n. l bs.) torque.
(c) Veri fy throttl e body duct i s ful l y seated to
i ntake mani fol d and ti ghten cl amp to 5 N·m (40 i n.
l bs.) torque.
(d) Connect the Throttl e Posi ti on Sensor (TPS)
and I dl e Ai r Control (I AC) connectors.
(e) Connect proporti onal purge sol enoi d (PPS)
and crankcase vent hose from throttl e body.
(24) Connect the battery cabl es.
(25) Road test vehi cl e and i nspect for l eaks.
Fig. 16 Starter Motor Removal/Installation—Typical
1 – BOLT
2 – GROUND
3 – STARTER
4 – BOLT
Fig. 17 Transaxle Upper Mount Thru-Bolt—Typical
1 – MOUNT BRACKET
2 – BOLT
3 – MOUNT
PL CLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)
RELEASE BEARING AND FORK
Remove the transaxl e from the vehi cl e. See Group
21, Transaxl e for removal and i nstal l ati on proce-
dures.
REMOVAL
(1) Move the l ever and beari ng assembl y to a ver-
ti cal i n-l i ne posi ti on. Grasp the rel ease l ever wi th
two hands i n the pi vot stud socket area. Pul l wi th
even pressure and the l ever wi l l pop off the pi vot–
stud. Do not use a screwdri ver or pry bar to pop off
the l ever. Thi s may damage the spri ng cl i p on the
l ever.
(2) As a uni t, remove the fork from the beari ng
thrust pl ate. Be careful not to damage retenti on tabs
on beari ng.
(3) Exami ne the condi ti on of the beari ng. It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(4) The beari ng shoul d turn smoothl y when hel d i n
the hand under a l i ght thrust l oad. A l i ght drag
caused by the l ubri cant fi l l i s normal . I f the beari ng
i s noi sy, rough, or dry, repl ace the compl ete beari ng
assembl y wi th a new beari ng.
(5) Check the condi ti on of the pi vot stud spri ng
cl i ps on back si de of cl utch fork. I f the cl i ps are bro-
ken or di storted, repl ace the cl utch fork.
INSTALLATION
(1) The pi vot bal l pocket i n the fork, as wel l as the
fork arms shoul d be l ubri cated wi th grease pri or to
i nstal l ati on.
(2) Assembl e the fork to the beari ng. The smal l
pegs on the beari ng must go over the fork arms.
(3) Sl i de the beari ng and fork assembl y onto the
i nput shaft beari ng retai ner, as a uni t.
(4) Snap the cl utch fork onto the pi vot bal l .
(5) Rei nstal l transaxl e assembl y. Refer to Group
21, Transaxl e for further i nformati on.
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , grease, water, or other fl ui ds on
the cl utch contact surfaces wi l l cause faul ty opera-
ti on.
Duri ng i nspecti on, note i f any components are con-
tami nated. Look for evi dence of oi l , grease, or water/
road spl ash on cl utch components.
OIL CONTAMINATION
Oi l contami nati on i ndi cates a l eak at the rear mai n
seal and/or transaxl e i nput shaft. Oi l l eaks produce a
resi due of oi l on the transaxl e housi ng i nteri or, cl utch
Fig. 18 Transaxle Removal/Installation
1 – MODULAR CLUTCH ASSEMBLY
2 – CLIP
3 – TRANSAXLE
4 – CLUTCH MODULE BOLT (4)
VIEW A
6 - 12 CLUTCH PL
REMOVAL AND INSTALLATION (Continued)
cover and fl ywheel . Heat bui l dup caused by sl i ppage
can bake the oi l resi due onto the components. Thi s
gl aze-l i ke resi due ranges i n col or from amber to
bl ack.
GREASE CONTAMINATION
Grease contami nati on i s usual l y a product of over-
l ubri cati on. Duri ng cl utch servi ce, appl y onl y a smal l
amount of grease to the i nput shaft spl i nes. Excess
grease may be thrown off duri ng operati on, contami -
nati ng the di sc.
ROAD SPLASH/WATER CONTAMINATION
Road spl ash contami nati on i s usual l y caused by
dri vi ng the vehi cl e through deep water puddl es.
Water can be forced i nto the cl utch housi ng, causi ng
cl utch components to become contami nated. Faci ng of
di sc wi l l absorb moi sture and bond to the fl ywheel
and/or, pressure pl ate, i f vehi cl e i s al l owed to stand
for some ti me before use. I f thi s condi ti on occurs,
repl acement of cl utch assembl y may be requi red.
Dri ve the vehi cl e unti l normal cl utch operati ng tem-
perature has been obtai ned. Thi s wi l l dry off di sc
assembl y, pressure pl ate, and fl ywheel .
CLEANING PRECAUTIONS
Condensati on from steam vapors tend to accumu-
l ate on the i nternal cl utch mechani sm when the vehi -
cl e i s steam cl eaned. Faci ng of di sc wi l l absorb
moi sture and wi l l bond to fl ywheel and/or pressure
pl ate, i f vehi cl e i s al l owed to stand for some ti me
before use. I f thi s condi ti on occurs, i t may requi re
repl acement of cl utch assembl y. After cl eani ng, dri ve
the vehi cl e to i ts normal cl utch operati ng tempera-
ture. Thi s wi l l dry off di sc assembl y, pressure pl ate,
and fl ywheel .
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Modul ar Cl utch-to-Dri ve Pl ate Bol ts . . . . . 88 N· m
(65 ft. l bs.)
Transaxl e-to-Engi ne Mounti ng Bol ts . . . . . . 95 N·m
(70 ft. l bs.)
PL CLUTCH 6 - 13
CLEANING AND INSPECTION (Continued)