w cute CLUTCH ‘TABLE OF CONTENTS pace page cuwren INSTALLATION DESCRIPTION + LINKAGE: ‘OPERATION 4 REMOVAL ° WARNING 2 INSTALLATION ° DIAGNOSIS ANO TESTING - CLUTCH 2 MASTER CYLINDER SPECIFICATIONS-CLUTCH 5 “INSPECTION 0 ‘cuureH ose ‘CLUTCH PEDAL REMOVAL 6 “REMOVAL 0 REMOVAL 7 “DESCRIPTION * INSTALLATION 7 OPERATION " FLYWHEEL, DIAGNOSIS AND TESTING - CLUTCH PEDAL DESCRIPTION 7 “Postmion swutcH " DIAGNOSIS ANG TESTING | FL¥WHEEL @ INSTALLATION # PILOT BEARING REMOVAL e CLUTCH OPERATION “The chtch operates wich leverage, clamping force DESCRIPTION and trition The dine serves‘ the fton element ‘The clutch mechanism consists of yuh, dy type aise. élaphragm sie presse plate ad hydraulic linge, The Rywhee! bolted f the sear Mlange of the crankshaft. The dutch pressure plate i batted to the Mwheel wath the euch aise betveen these two components. The luteh system provides transinssion. The system is desiged to transfor the torque output of the engine, to the transmission ‘while lating the transmis from the engine fr ing pulses to minimize concerns such av gear rattle lamping fore. The clutch pedal. hydraulic nkage release fever and bearing prove che leveroue "The chtch master cylinder puss roe eneted to the clutch pedal” When ‘the clutch pedal 1s pressed, the Slave cylinder operated” by the ‘dutch master cylinder mounted on the dash pare! The release fork In acute by the Fydraule slave (lier aumted on the transmission housing. The Folease bearing is operated by a release fork plvoing ‘na ball std mounted in the transmission housing The vekaxe tearing ten depresies Ue prea’ plate spring fingers chereby releasing pressure at the dutch dis end allowing the engine cranksha o ‘Spin Independently ofthe transmission Input sha6-2 cluTcH CLUTCH (Continued) WARNING CLUTCH COMPONENTS. FACTORY INSTALLED CLUTCH DISCS DO NOT CONTAIN. ASBESTOS FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY CONTAIN ASBESTOS. FIBERS FROM AFTERMAR- KET COMPONENTS. BREATHING EXCESSIVE CON- CENTRATIONS OF THESE FIBERS CAN CAUSE ‘SERIOUS BODILY WARM. WEAR A RESPIRATOR ‘COMPONENTS WITH COMPRESSED AIR OR WITH ‘ADRY BRUSH. EITHER CLEAN THE COMPONENTS UUM CLEANER SPECIFICALLY DESIGNED. FOR REMOVING ASBESTOS FIBERS AND DUST. 00 NOT CREATE DUST BY SANDING A. CLUTCH DISC. DAMAGED OR CONTAMINATED. DISPOSE OF ALL DUST AND DIRT CONTAINING ASBESTOS FIBERS IN SEALED BAGS OR CONTANERS. THIS WILL HELP MINIMIZe EXPOSURE TO YOURSELF AND TO ‘OTHERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAPETY AND HEALTH ADMINISTRATION (OSHA) (EPA), FOR THE HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. DIAGNOSIS AND TESTING - CLUTCH Drive the vehicle a rial sped. Shi the trams ission dough all ear rants and abserve duchy Seton hee ater rat io te a Potent the problem Is rats or hard ig. fr ther lagoons may be needed as the transmission oF {nother dveline component may be ot fault NOTE: Vehicles equipped with @ Dual Mass Fiy- ‘wheel may produce arate when the engine Is shut ‘off This noe fs considered norm ‘CLUTCH CONTAMINATION Fluid cantaminaton #5 a Fequent couse af catch malfintins, Oi water or lich Mn on the cite {Ge and pressure plate surfaces wil cause chatter Slip and grab Inspect components for ol. Hrsalc Mula or water/oad splash contamination, ‘Ol contamination indcates a Teak a elther the rear main seal or transmission snp shafe Clutch push ra sects. Heat buildup caused by slippage beeween the pressure plate, dsc and fywhee con ake the el residue antathe component The glace Uke reside ranges in ear frm aber to black 1 Road splash contamination is dirtvater entering the clutch Pousig due to base bolts, housing cracks IMPROPER RELEASE OR CLUTCH ENGAGEMENT ty wear oF damage clutch components A visual Ispection of the elease components will usually reveal the problem part. interconnecting Kine end hose slave cylinder bolts, Also worse release fork, pivot std, clutch dls pressure plate or release bering Engaperent problens can resalt i slip, chatert shudder and nosy operation ‘The causes may be ‘dutch ise contamination, wear, astorion or fy ‘hee! dame Visually inspect to determine the ‘actual cause ofthe problem, ‘CLUTCH MISALIGNMENT CChtch camponents must te in proper alignment with the crankehaft and trtrsmission input sha “Missignment caused ty excessive runout or warpage tay cht open wt eau gr, che PRESSURE PLATE AND DISC RUNOUT ‘Check the clutch disc Refre Installton. Axial (fae) runt fs new he saul at ceed 050 ‘rn (020 in). Measure rut about 6 rm (Uf Mom the ouer edge of the dsc focing Obtain warped caver or diaphragm spring will cause grab land incomplete ceease or engagement. Be careful ‘when handling the cover ar ds. Impact can ds Tab of the etch due ‘Use a alignment tol when positioning the disco ‘Arequent cause of eltch cover distortion (and corset age proper bak i FLYWHEEL RUNOUT ‘Check Mjowhee! runout whenever misalignment is to (0.003 in). Measure runout at the outer ede of the fywhee face witha dal Indicator, Moon he Intron ted aid np fo fe ‘Comionn causes of rancut arew CLUTCH (Continued) “eat warpage {improper machining incorrect bolt tein 1 improper seating on crankshaft flange shoulder foreign material on erenkshatt lange fend machining will egate Us feature. Minar ly ‘wheel scaring can be cleaned ip by hand ch 18D rit cmory or with surface grining equlpment Eemave any) enough material to reduce. Scoring (approximately 0001 "C003 in) Heavy” sock femowal i not recommended. Replace the Nywinel It scoring ts severe and deeper then (1076 mm (0.003 rocking or warpage eller installation. i can also cuutcH 6-3 ‘weaker the fiyahesl and imerfere with proper clutch release Niywheel, Dirt ard grease on the lage surlace me ‘ick the flywheel cusing excessive runaut, Use ne ats with Mopar Lark And. Seal ar equlvalont ‘Tighten Bybee bos ta specified torque only: Over jghening can dstort the. fywheel" hub. causing DIAGNOSIS CHART ‘The diagnasis charts Diagmsis Chart describe ‘onnion cltch problens causes an orrerton. Co ‘the indiveted columns. biAGNosis CHART CONDITION POSSIBLE CAUSES CORRECTION ie facing wom out 1 Norma! weer 2 Diver troquenty nie (aig) be teh Resuls in fn evernesting 5. Ingen exten cover doptragm sping tension, 1. pace cover and ds. 2. Replace cover and ie 3. Replace cover and se [Cutch is tocingcontamintes with Jot reese oF ctch tus hous. +. Leak a rear mein enaine sal or transmission Input shaft oa! 2, Excessive mount of grea89 appl the inp eat spines. 5. Road each, water entering 4 Stave cylinder leaking 1. Replace spropite sea 2. Remove grease and apply the onoct amount of grease 5. Replae cate isc. Clan catch ‘cover and reuse in good candi, 4. Replace hyeraue dutch snkage Cuchi unring partaty Scongaged, 1. Feloaso bearing sting or ining and does nat tum the normal rain poston 1. Verity are. Replace the rotease Fiyabee! bow minimum thickness 1. imeroper tyes! machining. Fyumea! nas oecasene taper oe xcensve matral removal 1. Replace tyes Jcutch die, cover andlor daha spring warped or stores procedre 1. Rough herding. Impact bent cover. sang, ores 2. Inroper bot ihtorng 1. Replace de o over 06 necessary 2. Tigton uth cover using proper procedre6-4 clurcH CLUTCH (Continued) 1 CONOTTION POSSIBLE CAUSES ‘CORRECTION Facng on fywnaei side of stom, gouge, or worn 1. yee surtace scared or rick, 2. Clu dis sting o binsing on tranamiasion input hat posable. Replace fywheel and diac 2. Leste splines wi igh temperature race, [cktch ic facing but. Fiywhoo! and cover pressure plate surfaces eaviy glaze, 1. Frequont operation under high Toads hard accateraton 2. Driver raquenty nia (eles) ‘teh Result in tps wear and ‘vemeating of dsc and cover, 1. Comet conan af yhoo and pressure plate surface, Replace problem cau 2. Comoe condition of fywheel and pressure plato surface, Replace problem cause fouich aise binds on put shat spines 1. Clutch asc ub splines damaged sing instaston 2. Input shat splines rah, damaged, or carded 1. Clean, smoeth, and brite hub spines possible. Replace ae necessary. 2. Clean, smoot, and bic ‘hat splines If posse. Replace input sha noceseay [curch i ested to Myhee! andlor pressure plate 1. Ctch not weed for and enendod pio of time (2 ong tem 1. Sond ristedsuraces wih 190 agit sanding peper. Replace clutch 2. Bearing detect. 8. Bearing not brated. 4. Clutch misaignment ec storae). over and fae frecessary Pict bearing soe, ose, or oles | 1. Beanng cocked ng 1. etal and nest are worn insaiaton bearing bearing 3. Intl and eat bearing 4 spect etch and correct 96 hecessary Install sa eae 2 now bosons cuich wit not isongage proper 1 Low oth Wid eve 3. Cltn dis tent or dstorte 4 Chtch cover dasteagm spmng bent or warped 8. Relaso ork bot or fork pivot loose oF damaped 7. Clutch master or save eyinder 1. place hyerau inkage assembly 2. alow popar bothering procedure 3. Roplace obtch eae 4 Replace catch cove. onset 8. Replace fork or pivot a6 7 Replace mydrule tinkose esew CLUTCH (Continued) cuTcH 6-5 CONOTTION POSSIBLE CAUSES ‘CORRECTION [cunch peas squeak 1. Pot pn tose 2. Master eyinder bushing not eats, 5. Pedal bushings worn out or 1. Tighten pt init posse Replace clutch pedal neccesary 2. Lubreste moter eyinder busting. 5. Replace and uibicste bushings. [Ckich master or elaveeyingor ptnger acing andor texeng components wm or cred, 1. Replace lth hyrauli inkage assembly Retease bearing Is roy, 1. Release deang detecave or damaged 1. Replace release bearing. contact eurtace of release baaring amaze. 1, Cch over incarect or elesee fagors bert o Store, 2 Release bearing detective or damaged 5. Roloaso bearing misagnod 1. Replace cltch cover ane vloase bearing 2 Replace he release bearing 3. Check and caret nat of ‘htch coments. Check font bearing sleeve for damage! alignment. Rapa 99 necessary Prat engapomont of cuich se. Jone ise of dic Is worn and the etree glazed and ighoy 1. lich preseure plate postion 2. Clutch cover, sping, of ees fngors bert or stares 5. Chon die comaged or ‘iota 4. Clutch misalignment 1. Replace elth dias and cover, 2. Replace clutch oss and cove 2. Replace catch ese 4. Chock aimont and runt of ‘jure, die, pressure plate, andar chien Reusing, Contec necessary. SPECIFICATIONS-CLUTCH TORQUE SPECIFICATIONS DESCRIPTION War Fibs, Te bbe: Tian Cover Bots -2aL 31 Ea Guten Cover Bos -40C Ey a ‘Chick Gynaer Bats Ea : 200 ‘Gian Rousing o Engine Bae 75 = = ‘Chich Rousmng io rans Bots a ea ‘Dust Shad Bote a Fea Bots aL 35 70 Fiyatee! Bots 01 1 75 Troserember Frame Soe a w6-6 clUuTCH CLUTCH DISC REMOVAL (0) Remove transmission. Refer to 2 Transmission ‘and Transfer Case for procedures, (2) Ir original clutch cover il be reinstalled, marke pasion of cover on Miywhee! for assembly reference Use paint or a seriber for this prone (G) Ir clateh cover tobe replaced, cover blls can te removed in any sequence, ‘CAUTION: if original cover will be reused, loosen ‘cover bolts evenly and in rotaon to relieve spring tension equal. This ry to avold warping (4) Remove cover bolts and remave cover and dsc ig. 0) Fig. 1 Clute Disc And Pressure Plato INSTALLATION (1) Lightly scuff sand Myowhect foe with 180 gr {2 Lubricate plot bearing with Mopar high term erature bearing prem (3) Poston eiueh ise on Ayla! with side rmerked Myce positioned against lye 1 NOTE: If disc is not marked, fat side of disc hub ‘goes towards the fijuhec. ig, 2 Aligning Clutch Dise (6) Poston pressure plate over dise and on fy shes Fig 2) (6) nat eutch caver bats finger igh (7) Tien cover bolts evenly are i coation & few threads a @ tne Tighterig bots to 1 Nim (23 Fibs) on 251 engines and 50 No (37. Ths) on NOTE: Cover bots must be tightened eveny and to ‘specfed torque fo avd distorting cover (8) Apply ta bearing grea splines of tnsmission input shaft. Do not over Tubricate shaft splines: ‘This will" result" ease coctaraination of diss (0) Testa! the (ranma equivalent to cuteh ise hab apdw CLUTCH RELEASE BEARING REMOVAL (a) Remove the tonsnission. (2) Disconnet release bearing fom release lever ‘and remove bearing (Pig. 3 (G) Inspect bearing side surface of transmission 1a) tnspect release frk and fork pivut, Be sure pivot is secure ant gond condition. Be sre fork Fig, 3 Release Bearing INSTALLATION (0) Labricate crankshaft pilot bearing, input sha splines. bearing retainer sie surface, fork pivot ond (2) Enatall mew elesse bearing. Verify sring i rp eared rae FLYWHEEL DESCRIPTION STANDARD FLYWHEEL “The standard Mpwheo! te used on the 4. engine ‘The Reet (ig 4) ty hey plate bolted to the rear of te crankshaft. "The fiywheel incorporates the fing wear around the outer ceumference to mesh Tae of te yee serves as the deving mens 19 the clutch dae, ‘DUAL MASS FLYWHEEL ‘The Dual Mase Flywheel is used an che 24L engine (Fig. 5). The Ayshee! incorporates the Trg fear arvund the outer circumference to mess with the stare to permit engine cranking The primary Mywheet sie is bed tothe craikshall. The second ‘ary Tyee face serves a the driving member to the ‘ch dis, Internal springs Between the Mywhecls Fig. 5 DUAL MASS FLYWHEEL6-8 cluTcH FLYWHEEL (Continued) ‘OPERATION The Mywheot serves to dampen the engine eng pulses, The heavy weight of the Msbee relative to the rotating mass of the engine exponents serves (0 ‘sablize the flaw of power to the remainder of the Geivetrain, The cramlahaft has the. tendency to the cylinder ring pulses, The flywheel dampens ese impulses by absorbing energy’ when te crank System when the erankshate slows ovr, ‘Ona Dual Mass Fiywheel che ational secondary mass aupled to tie transmission lowers the nara Frequency of the (ransminan rtating element, This decreases the Uansmibsion gear raile. The damper ‘Springs beeween the two Oyshoe! masses replace the clutch aise damper spring’ end assist in a sinooth ‘CAUTION: The Dual Mass Fiywheel is serviced 25 ‘an assembly only and should never be taken apart. DIAGNOSIS AND TESTING - FLYWHEEL ‘Check fywheel runout whenever misalignment is ‘auspected. Flywheel runt should nat exceed 008 tm (0003 In. Measure runout atthe outer edge of the Aywheel face with e dal ineatae Mount che Inictor an stud tstalle in ple of one ofthe ‘whet bole ‘heat warpage 1 improper machining 1 Incareect balk tightening {ore ego crank Daye sheer Fywhec machining Is noc recommended. The fy wheel catch surface Is machined to anc conta Wheat scoring ean be cleaned up by hand with 180 uit emery or with surfoce grinding equipment Remave only enough material to reduce scoring (approximately 0.001" O03. in)” Heawy stock Fentoval i mot recosamended. Replace the Rye! I scoring s severe and deeper then 0.076 mm (008 In). Excessive stck removal can result tn Miywheel weaker the ywteel ad interfere with proper catch 1 ‘Clean the crankshaft ange before mounting the Nywheel. Dire and grease on the Mange surface moy Cock the fiver! csng exessive rina. Use te aks with Mopar Lack” And. Seal or equivalent “Thahten yet bolls ta specified torque only Over PILOT BEARING REMOVAL (1) Remove the ransmission, (2) Remave pressure plate and clutch dis. (3) Remove lot tearing with om internal ind Pe per INSTALLATION 1) Lubricate new bearing with Mopar high tem perature bearing grease or equiva (2) Start nem bearing tne crankshaft by hand ‘Then set bearing with elute aligment tol (Fig 8 LD Net” {Ko Fig. 6 Pliot Bearing installer a (9) Lightly self sand yee! surface with 180 rit emery cloth, Then clean surfoce with wax ed Brease remover: {a} install itch dlse and pressure plate (5) Install the trarsmisionw LINKAGE REMOVAL ‘Catch master eytinder, slave inde and eonect tng line are serviced as att essebly ony. Camp rents cannot be overhauled of serviced separately Cylinders "and connecting. line are. sealed unis Nand deve models are basically the sare (1) Raise vehicle (2) Remove fasteners attaching slave cylinder 10 (3) Remove slave cylinder from clutch housing cra UW) Disengage catch Ma tne fromm body lis. (5) Lower vehicle (6) Nerty tat cap on catch master einer reser vai is tight. This i necessary to avid piling uid ‘uring removal (7) Remmve luich master einer attaching, mts (ig Tor ie 8, (2) Disengage copnured bushing on clutch master ‘inter etuatr om pivot pin on pedal arm, (9) Side actuator ff pivot pl Woy Disconnect teh tterlack salery. switch (1) Remove clutch hydraulle linkage rough engine compariment. Fig, 7 Left Hand Drive Clutch Linkage cuutcH Fig. 8 Right Hand Drive Clutch Linkage INSTALLATION ‘Ctch master cylinder, slave eylinder and connect Ing line are serviced an assenbly only. Carpe ‘ents connat be overhauled or serviced separately Cinders and connecting Line ere sealed units Remonatinsallaion proveires fr right and Tet {U)Be sare eeseroir cover on clutch master eli er is tg to avoid spills (2) Poston sate Tinkeage companones ip vehicle Work coonecting ine and slave eyinder dawnard pest engine and adjacent to cute oust. {3) Poston clutch mascereyinder on desh panel (a) Attach clutch master eller actuator co pvt ino lr pea (9) stall ond ughten ute master elinder ‘attaching nuts 0 38 Nan [28 TI) (6) Raise vette (7) Insert slave cylinder push rod through cate housing opening and inp release lever Be sure cap cn end of rod Is securely engaged in lever. Check this ‘efore installing evinder attaching nuts (6) tall and ighten slave eylder actaching, ruts to 28 Nom (17 Me bs 10) Secure clutch fuk line in body and transis {10} Lower vice {U1} Connect lath interac safety switch wire,6-10 CLUTCH. MASTER CYLINDER INSPECTION The clutch flld ceservoi, master cylinder, slave ‘linder and Mud ines are pre-e With fad at the factory during assembly operations. "The hydraule system should not requite adltonal uid evel ‘will actually. increase as normal ‘latch wear occurs, Avid over ing Mula from the reservoir. othe. reservoir. With the cap. and” daphragm removed Thuld level should not be above nletor inspection. wipe teservoir and cover clean before removing the cap CLUTCH PEDAL REMOVAL 1) Remove steering clumn lower ever and knee acer for acess (2) Disconnect clutch pedal postion switch wires (5) Dicengape captured bushing lock tabs attach ing clutch taster eylinder eluor te pedal pivot (Fig. 9) or ig. 10, @) Remove nuts attaching pedal and bracket to ash panel and upper col support (Fg. 9) (Ph 10, (@) Separate pedal assemble fram vehicle INSTALLATION (1) Place dutch pedal and bracket over studs on rand cot support (2) install mute to attach pedal and bracket 10 ash panel and upper ow! bupport. Tighter ats So Nam G91 ths) (a) Conner cluieh pedal postion switch wines 1 Fig. 9 CLUTCH PEDAL MOUNTING-LHO Fig, 10 Clutch Pedal Mounting RMDw CLUTCH PEDAL POSITION SWITCH DESCRIPTION “he Clutch Pedal Poon Sitch (CPPS) i cated ‘Sutch meter endo vd ig) Te wing Harese connection forthe sth ade sie of the vehicle under the Teeside of the Instrument panel ig 12) ‘Fg. 11 CLUTCH PEDAL POSTON SWITCH (CPPS) ‘OPERATION ‘The chtch pal poson sich is wed to prevent starter motor engagement ‘ness the utc pedal Is Rett rom teste is ako sed 4 stat dwn andor prevent operation he pe con trl system when the clu peda is deprensed cLUTCH 6-11 Fig, 12 CPPS ELECTRICAL CONNECTION DIAGNOSIS AND TESTING - CLUTCH PEDAL. POSITION SWITCH (0) Locate sith 2-wire electrical connector under Inserument panel (Pg. 12) Disconnect wiring atts (2) Cheek for site continuity with an obeameter hile operating eluch pedal up and dwn Contin ty shal be broken and reapplied each time pedals TSI It continuity is not present. or is elways presant at ny peda pti. reploe sth. Switch Fr oe served separates: Replace citch master cx REMOVAL Sch mt ev eae: Hah pice INSTALLATION Switch Is not served separately. Iswtch replace