Clutch: Service and Repair

Improper operation or excessive wear may impair the clutch function to a point where it may be necessary to remove and replace the disc and/or cover assembly. Handle the clutch and the disc carefully to avoid contaminating the friction surfaces.

REPLACEMENT





Remove the transmission.





Remove the clutch housing, release fork and bearing assembly.

Mark the clutch cover and flywheel, to maintain their same relative positions when reinstalling clutch assembly.





Insert a universal alignment tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings.





Loosen the clutch cover attaching bolts. Remove the clutch cover assembly and disc from the flywheel.





Remove the flywheel from the crankshaft. Handle the clutch cover assembly and flywheel carefully to avoid contaminating the friction surfaces.





Inspect for oil leakage through the engine rear main bearing oil seal. If leakage is noted, it should be corrected at this time.





The friction face of the flywheel should have a uniform appearance throughout the entire clutch contact area. If there is evidence of heavy contact on one portion of the wear circle and a very light contact 1800 from that portion, the flywheel may be improperly mounted or sprung. In either case, a dial indicator mounted on the clutch housing with the plunger In contact with the wear circle, should show no more than 0.76mm [.003 inch] runout throughout complete rotation of the flywheel.





The friction face of the flywheel should also be free from excessive discoloration, burned areas, small cracks, grooves or ridges. Wipe the friction surface of the flywheel with kerosene, mineral spirits or other suitable solvent.





The drive pinion pilot bushing, pressed in the rear end of the crankshaft, should be smooth and show no excessive wear. The bushing l.D. must be no more than 0.127mm [0.005 inch] out of round.





The end of the transmission main drive pinion should be smooth and bright, without grooves and ridges.





The disc assembly should be handled without touching the facings. Replace the disc if the facings show evidence of grease or oil soakage, or wear to within less than 0.015 inch of the rivet heads. The hub splines and splines on the transmission main drive pinion should be a snug fit without signs of excessive wear. Metallic portions of the disc assembly should be dry and clean and show no evidence of having been hot. Each of the arched springs between the facings should be unbroken and all rivets should be tight.





Wipe the friction surface of the pressure plate with kerosene, mineral spirits, or other suitable solvent.





Using a straightedge, check the pressure plate for flatness. The pressure plate friction area should be flat within 0.076mm [0.003 inch] and free from discoloration, burned areas, cracks, grooves or ridges.





The bearing contact area of the release diaphragm should have a uniform wear pattern.





Using a surface plate, test the cover for flatness. All sections around the attaching bolt holes should be in contact with surface plate.





Examine the condition of the clutch release bearing. The clutch release bearing is a prelubricated, sealed thrust bearing and should not be immersed in solvent. The bearing should turn freely when turned by hand under light thrust load, with no evidence of roughness. If the bearing is noisy, rough or dry, replace the complete bearing assembly with a new assembly.

INSTALLATION





The drive pinion pilot bushing in the end of the crankshaft requires a grease that will stay In place during high temperature operation. Use MOPAR Multipurpose Grease, Part Number 4318063 (or equivalent), which is a grease of this type and Is recommended for all clutch lubrication points.





Install the flywheel. Install the clutch cover assembly and disc on the flywheel, being careful to properly align the alignment marks made before removal. Insert a universal clutch alignment tool through the clutch disc into the pilot bearing to keep the disc centered while the cover plate capscrews are installed.

Torque Value:

Flywheel to Crankshaft 137 N-m [101 ft-lbs]
Clutch Cover to Flywheel 23 N-m [17 ft-lbs]





CAUTION: To avoid distortion of the clutch cover, the bolts should be tightened a few turns at a time, alternately, until they are all seated. Tighten to specifications. Remove the clutch disc alignment tool.





Install the clutch housing and torque all the clutch housing to engine block bolts.

Torque Value:

Clutch Housing to Engine Bolts (3/8") 41 N-m [30 ft-lbs]
Transmission to Clutch Housing Mounting (3/8") 47 N-m [35 ft-lbs]