Dodge Clutch Service Manual
DR CLUTCH 6 - 1
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION ..........................1
OPERATION ............................1
WARNING .............................2
DIAGNOSIS AND TESTING ................2
SPECIFICATIONS ........................6
CLUTCH DISC
REMOVAL .............................6
INSTALLATION ..........................6
CLUTCH HOUSING
DIAGNOSIS AND TESTING ................8
REMOVAL .............................10
INSTALLATION .........................10
CLUTCH RELEASE BEARING
REMOVAL .............................11
INSTALLATION .........................11
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, a single, dry-type disc, and a diaphragm style clutch cover
(Fig. 1). A hydraulic linkage is used to operate the
clutch release bearing and fork. The flywheel is
bolted to the rear flange of the crankshaft. The
clutch pressure plate is bolted to the flywheel with
the clutch disc located between these two components. The clutch system provides the mechanical,
but still easily detachable, link between the engine
and the transmission. The system is designed to
ensure that the full torque output of the engine is
transfered to the transmission while isolating the
transmission from the engine firing pulses to minimize concerns such as gear rattle.
FLYWHEEL
DIAGNOSIS AND TESTING ................11
REMOVAL .............................12
DISASSEMBLY .........................12
ASSEMBLY ............................12
INSTALLATION .........................12
PILOT BEARING
REMOVAL .............................12
INSTALLATION .........................12
LINKAGE
REMOVAL .............................13
INSTALLATION .........................13
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION .........................14
OPERATION ...........................14
DIAGNOSIS AND TESTING ................14
OPERATION
Leverage, clamping force and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydraulic linkage, release lever and bearing provide the
leverage.
The clutch master cylinder push rod is connected
to the clutch pedal. When the clutch pedal is
depressed, the slave cylinder is operated by the
clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave
cylinder mounted on the transmission housing. The
Fig. 1 ENGINE POWERFLOW
release bearing is operated by a release fork pivoting
on a ball stud mounted in the transmission housing.
The release bearing then depresses the pressure
plate spring fingers, releasing pressure on the clutch
disc and allowing the engine crankshaft to spin independently of the transmission input shaft (Fig. 2).
6 - 2 CLUTCH DR
CLUTCH (Continued)
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING
A road test and component inspection is recommended to determine a clutch problem. During a
road test, drive the vehicle at normal speeds. Shift
the transmission through all gear ranges and observe
clutch action. If the clutch chatters, grabs, slips or
does not release properly, remove and inspect the
clutch components. If the problem is noise or hard
shifting, further diagnosis may be needed as the
transmission or another driveline component may be
at fault.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, water or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter,
slip and grab. Inspect components for oil, hydraulic
fluid or water/road splash contamination.
Fig. 2 CLUTCH OPERATION
1 - FLYWHEEL
2 - PRESSURE PLATE FINGERS
3 - PIVOT POINT
4 - RELEASE BEARING PUSHED IN
5 - CLUTCH DISC ENGAGED
6 - CLUTCH DISC ENGAGED
7 - RELEASE BEARING
WARNING
WARNING:: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMARKET COMPONENTS. BREATHING EXCESSIVE CONCENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VACUUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
Oil contamination indicates a leak at either the
rear main seal or transmission input shaft. Clutch
fluid leaks are usually from damaged slave cylinder
push rod seals. Heat buildup caused by slippage
between the pressure plate, disc and flywheel can
bake the oil residue onto the components. The glazelike residue ranges in color from amber to black.
Road splash contamination is dirt/water entering
the clutch housing due to loose bolts, housing cracks.
Driving through deep water puddles can force water/
road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems can be
caused by worn or damage clutch components. A
visual inspection of the release components will usually reveal the problem part.
Release problems can result in hard shifting and
noise. Look for leaks at the clutch cylinders and
interconnecting line and loose slave cylinder bolts.
Also worn/loose release fork, pivot stud, clutch disc,
pressure plate or release bearing.
Engagement problems can result in slip, chatter/
shudder and noisy operation. The causes may be
clutch disc contamination, wear, distortion or flywheel damage. Visually inspect to determine the
actual cause of the problem.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
DR CLUTCH 6 - 3
CLUTCH (Continued)
CLUTCH COVER AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of a new disc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain
another disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalignment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tightening.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator.
Common causes of runout are:
• heat warpage
• improper machining
• incorrect bolt tightening
• improper seating on crankshaft flange shoulder
• foreign material on crankshaft flange
Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180
grit emery or with turning equipment. Remove only
enough material to reduce scoring (approximately
0.001 - 0.003 in.). Heavy stock removal is not rec-
ommended. Replace the flywheel if scoring is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken the flywheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction.
Fault conditions are listed at the top of each chart.
Conditions, causes and corrective action are outlined
in the indicated columns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
Clutch is running partially
disengaged.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
3. Insufficient clutch cover
diaphragm spring tension.
1. Leak at rear main engine seal or
transmission input shaft seal.
2. Excessive amount of grease
applied to the input shaft splines.
3. Road splash, water entering
housing.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
1. Release bearing sticking or
binding and does not return to the
normal running position.
2. Replace cover and disc.
3. Replace cover and disc.
1. Replace appropriate seal.
2. Remove grease and apply the
correct amount of grease.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
6 - 4 CLUTCH DR
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Flywheel below minimum thickness
specification.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
Facing on flywheel side of disc torn,
gouged, or worn.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Rough handling. Impact bent
cover, spring, or disc.
2. Improper bolt tightening
procedure.
1. Flywheel surface scored or
nicked.
2. Clutch disc sticking or binding on
transmission input shaft.
1. Frequent operation under high
loads or hard acceleration
conditions.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
1. Replace flywheel.
1. Replace disc or cover as
necessary.
2. Tighten clutch cover using proper
procedure.
1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Inspect components and
correct/replace as necessary.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.
Clutch disc rusted to flywheel and/or
pressure plate.
Pilot bearing seized, loose, or rollers
are worn.
1. Clutch disc hub splines damaged
during installation.
2. Input shaft splines rough,
damaged, or corroded.
1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).
1. Bearing cocked during
installation.
2. Bearing defective. 2. Install a new bearing.
3. Bearing not lubricated. 3. Install a new bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
1. Install a new bearing.
necessary. Install and lubricate a
new bearing.
DR CLUTCH 6 - 5
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Clutch will not disengage properly. 1. Low hydraulic linkage fluid level. 1. Add hydraulic linkage fluid.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
6. Release fork bent or fork pivot
loose or damaged.
7. Clutch master or slave cylinder
failure.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
2. Master cylinder bushing not
lubricated.
3. Pedal bushings worn out or
cracked.
4. Rough surface on front bearing
retainer.
4. Replace clutch cover.
correctly.
6. Replace fork or pivot as
necessary.
7. Replace hydraulic linkage
assembly.
Replace clutch pedal if necessary.
2. Lubricate master cylinder
bushing.
3. Replace and lubricate bushings.
4. Replace front bearing retainer.
Clutch master or slave cylinder
plunger dragging andør binding
Release bearing is noisy. 1. Release bearing defective or
Contact surface of release bearing
damaged.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Master or slave cylinder
components worn or corroded.
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
2. Release bearing defective or
damaged.
3. Release bearing misaligned. 3. Check and correct runout of
1. Clutch pressure plate position
incorrect.
2. Clutch cover, spring, or release
fingers bent or distorted.
3. Clutch disc damaged or
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
1. Replace clutch hydraulic linkage
assembly.
1. Replace release bearing.
1. Replace clutch cover and release
bearing.
2. Replace the release bearing.
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
1. Replace clutch disc and cover.
2. Replace clutch disc and cover.
2. Replace clutch disc.
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
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