Clutch Disc: Service and Repair

CLUTCH DISC

REMOVAL
1. 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 assy. (Fig. 6) 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. 6) and partially remove air cleaner assembly.
e. Disconnect accelerator and speed control (if equipped) cables after the assy. 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. 7) (Fig. 8).





8. Remove shift cable-to-bracket clips (Fig. 9).
9. Disconnect shift selector and crossover cable from levers (Fig. 9). Remove cables and secure out of the way.





10. Disconnect the vehicle speed sensor connector (Fig. 10).
11. Raise vehicle on hoist.
12. Remove transaxle oil drain plug and drain oil into a suitable container.
13. Remove both half shafts.





14. Remove starter motor (Fig. 11).
15. Support engine at oil pan with screw jack and wood block.





16. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house (Fig. 12).
17. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
18. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts.
19. Remove transaxle from vehicle.
20. Remove bolts holding the clutch pressure plate to the flywheel.
21. Remove the clutch pressure plate and disc from the flywheel.
22. Remove the bolts holding the flywheel to the engine crankshaft.
23. Remove the flywheel from the crankshaft.

INSTALLATION
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary.
2. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed.
3. Inspect the clutch disc for the side marked "FLYWHEEL SIDE".
4. Apply a very light coating of grease to the splines in the clutch disc hub.
5. Position the flywheel onto the engine crankshaft.
6. Install the bolts to hold the flywheel to the crankshaft. Tighten the bolts to 95 Nm (70 ft. lbs.).
7. Position the clutch disc to the flywheel.
8. Install the clutch pressure plate to the flywheel. Finger tighten the pressure plate bolts.
9. Use Clutch Alignment Tool 6724 to position the clutch disc to the center of the flywheel.
10. Tighten the clutch pressure plate bolts in a criss-cross pattern to 28 Nm (250 inch lbs.).
11. Install transaxle into position. Be sure to carefully guide the input shaft splines through the clutch disc. It may be necessary to slightly rotate the transaxle or flywheel to allow the splines to engage.
12. Install transaxle-to-engine mounting bolts and tighten to 108 Nm (80 ft. lbs.) torque.
13. 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. 12).
14. Remove screw jack.
15. 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. 11).
16. Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque.
17. Install both front axle driveshafts.
18. Fill transaxle with suitable amount of Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Fill height is 3/16" (4.76 mm) below bottom of fill hole.
19. Lower vehicle.
20. Connect vehicle speed sensor connector (Fig. 10).
21. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 9).
22. 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.
23. Connect back-up lamp switch connector.
24. Connect ground strap to transaxle upper mount bracket.
25. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery.
26. Install the air cleaner/throttle body assy. as follows:
a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assy.
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.
27. Connect the battery cables.
28. Road test vehicle and inspect for leaks.