Clutch Cover and Disc Removal and Installation

CLUTCH COVER AND DISC REMOVAL

(1) Remove transmission and transfer case. Service and Repair
(2) If original clutch cover will be reinstalled, mark position of cover on flywheel for assembly reference. Use paint or a scriber for this purpose.
(3) If clutch cover is to be replaced, cover bolts can be removed in any sequence. However, if original cover will be reinstalled, loosen cover bolts evenly and in rotation to relieve spring tension equally. Loosen bolts a few threads at a time to avoid warping cover.






(4) Remove cover bolts and remove cover and disc (Fig. 6).

CLUTCH COVER AND DISC INSTALLATION

(1) Lightly scuff sand flywheel face with 180 or 220 grit emery cloth. Then clean surface with a wax and grease remover.
(2) Lubricate pilot bearing with Mopar high temperature grease.
(3) Check runout and free operation of a new clutch disc as follows:
(a) Slide disc onto transmission input shaft splines. Disc should slide freely on splines.
(b) Leave disc on shaft and check face runout with dial indicator. Check runout at disc hub and about 6 mm (1/4 in.) from outer edge of facing.
(c) Face runout should not exceed 0.5 mm (0.020 in.). Obtain another clutch disc if runout exceeds this limit.
(4) Insert clutch alignment tool in clutch disc.






(5) Insert alignment tool in pilot bearing and position disc on flywheel. Be sure disc hub is positioned correctly. Side of hub marked Flywheel Side should face flywheel (Fig. 6).
(6) Position clutch cover over disc and on flywheel.
(7) Install clutch cover bolts finger tight.
(8) Tighten cover bolts evenly and in rotation a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. Correct tightening torques are: 31 N.m (23 ft. lbs.) on 2.5L engines and 54 N.m (40 ft. lbs.) on 4.OL engines.
(9) Apply light coating of Mopar high temperature grease to splines of transmission input shaft. Do not overlubricate shaft splines. This can result in grease contamination of disc.
(10) Install transmission and transfer case, if equipped. Service and Repair