Clutch Disc: Service and Repair
REMOVAL1. Raise hood.
2. Disconnect and isolate both battery cables, remove battery hold down clamp and bolt, and remove battery.
3. Remove air cleaner/throttle body assembly (Fig. 24) as follows:
a. Disconnect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body.
b. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
c. Disconnect throttle body air duct at intake manifold.
d. Remove mounting bolt and nut (Fig. 24) and partially remove air cleaner assembly.
e. Disconnect accelerator and speed control (if equipped) cables after the assembly is removed from position. Remove air cleaner assembly from vehicle.
4. Remove battery tray from bracket.
5. Disconnect ground cable at battery tray bracket.
6. Disconnect back-up lamp switch connector.
7. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 25) (Fig. 26).
8. Remove shift cable-to-bracket clips (Fig. 27).
9. Disconnect shift selector and crossover cable from levers (Fig. 27). Remove cables and secure out of the way.
10. Disconnect the vehicle speed sensor connector (Fig. 28).
11. Raise vehicle on hoist.
12. Remove transaxle oil drain plug and drain oil into a suitable container.
13. Remove both axle shafts.
14. Remove structural collar (Fig. 29).
15. Remove the left engine-to-transaxle lateral bending brace (Fig. 29).
16. Remove bellhousing dust cover (Fig. 29).
17. Remove the right engine-to-transaxle lateral bending brace (Fig. 30).
18. Remove starter motor (Fig. 31).
19. Remove drive plate-to-clutch module bolts.
20. Support engine at oil pan with screw jack and wood block.
21. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house (Fig. 32).
22. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
23. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts (Fig. 33).
24. Remove transaxle from vehicle (Fig. 33).
25. Remove modular clutch assembly from transaxle input shaft.
INSPECTION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation.
During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/ road splash on clutch components.
OIL
Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black.
GREASE
Grease contamination is usually a product of over lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc.
ROAD SPLASH WATER
Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel.
Extreme use of steam cleaning equipment on the engine compartment or vehicle undercarriage can have the same effect.
INSTALLATION
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary.
2. Install clutch module onto input shaft. Install transaxle into position.
3. Install transaxle-to-engine mounting bolts (Fig. 33) and tighten to 95 Nm (70 ft. lbs.) torque.
4. Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount bracket. Install mount bolt and tighten to 108 Nm (70 ft. lbs.) torque (Fig. 32).
5. Remove screw jack.
6. Install NEW drive plate-to-clutch module bolts and progressively tighten all bolts in a criss-cross pattern until the modular clutch assembly seats against the drive plate. Final torque the bolts to 88 Nm (65 ft. lbs.) torque.
7. Install starter motor and tighten bolts to 54 Nm (40 ft. lbs.) torque. Make sure to fasten ground cable to upper starter bolt as shown in (Fig. 31).
8. Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque.
9. Install bellhousing dust cover (Fig. 29).
10. Install left engine-to-transaxle bending brace (Fig. 29).
11. Install structural collar (Fig. 29) as follows:
a. Position collar and install all bolts finger tight.
b. Tighten the collar-to-oil pan bolts to 3 Nm (30 inch lbs.) torque.
c. Tighten the collar-to-transaxle bolts to 108 Nm (80 ft. lbs.) torque.
d. Final torque the collar-to-oil pan bolts to 54 Nm (40 ft. lbs.) torque.
12. Install the right lateral bending brace and tighten bolts to 81 Nm (60 ft. lbs.) torque (Fig. 30).
13. Install both front axle driveshafts.
14. Fill transaxle with suitable amount of Mopar(R) Manual Transaxle Lubricant (PN 04874465).
15. Lower vehicle.
16. Connect vehicle speed sensor connector (Fig. 28).
17. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 27).
18. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
19. Connect back-up lamp switch connector.
20. Connect ground strap to transaxle upper mount bracket.
21. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery.
22. Install the air cleaner/throttle body assembly as follows:
a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assembly
b. Install assembly into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 Nm (120 inch lbs.) torque.
c. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 inch lbs.) torque.
d. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
e. Connect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body.
23. Connect the battery cables.
24. Road test vehicle and inspect for leaks.