exj_6a.pdf

CLUTCH

6 - 1

CLUTCH

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

CLUTCH COMPONENTS ....................1

CLUTCH HYDRAULIC SYSTEM ..............1

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC .................1

PILOT BEARING ..........................3

FLYWHEEL ..............................5

FLYWHEEL RING GEAR ....................7

SPECIFICATIONS

SPECIFICATIONS .........................8

SPECIAL TOOLS

SPECIAL TOOLS ..........................8

DESCRIPTION AND OPERATION

CLUTCH COMPONENTS

The clutch mechanism consists of a single, dry-type

clutch disc and a diaphragm style clutch cover. A

hydraulic linkage is used to operate the clutch disc

and cover. The clutch components are very similar to

those used in gas engine models.

A pilot bearing is used to support the transmission

input shaft. The bearing is seated in a separate,

removable housing bolted to the flywheel hub.

CLUTCH HYDRAULIC SYSTEM

The

clutch

hydraulic

system

should

not

require

additional fluid under normal circumstances.

NOTE: The reservoir fluid level will actually

increase as normal clutch wear occurs. For this rea-

son, it is important to avoid over filling, or remov-

ing fluid from the reservoir.

If inspection indicates additional fluid is needed,

add fluid from a sealed container only. Use Mopar

Fig. 1 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY

2 – ENGINE SPEED SENSOR

3 – PRESSURE PLATE RETAINING BOLTS

4 – CLUTCH COVER (PRESSURE PLATE)

5 – ENGINE OIL PAN

6 – PRESSURE PLATE RETAINING BOLTS

brake fluid, or an equivalent meeting standards SAE

J1703 and DOT 3. Do not use any other type of fluid.

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC

a star pattern to relieve spring tension equally. This

is necessary to avoid warping the cover.

(4) Remove

REMOVAL

(1) Remove the transmission. Refer to Group 21,

Transmission and Transfer Case for procedure.

(2) If the original clutch cover will be reinstalled,

mark position of cover on flywheel for assembly ref-

erence. Use paint or scribe for this purpose.

(3) If the 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 in

the

clutch

cover

bolts

and

remove

cover and disc (Fig. 1).

INSTALLATION

(1) Lightly scuff sand flywheel face with 180 grit

emery cloth. Then clean surface with brake cleaner.

(2) Lightly lubricate the pilot bearing with Mopar

high temperature bearing grease.

6 - 2

CLUTCH

REMOVAL AND INSTALLATION (Continued)

Fig. 2 Clutch Components (VM Diesel)

1 – ENGINE BLOCK

2 – FLYWHEEL

3 – CLUTCH HOUSING AND TRANSMISSION

4 – CLUTCH COVER

5 – CLUTCH DISC

(3) Check free operation of clutch disc by sliding

disc

onto

transmission

output

shaft

splines.

Disc

should slide onto splines freely without binding.

(4) Position the clutch disc on flywheel. Be sure

side of disc marked “flywheel side” is positioned

against flywheel (Fig. 3). If disc is not marked, be

sure flat side of disc hub is placed toward the fly-

wheel.

(5) Insert

the

clutch

alignment

tool

(Fig.

clutch disc and pilot bearing.

(6) Position the clutch cover over the disc and on

the flywheel (Fig. 5).

(7) Install the clutch cover bolts finger tight (Fig.

5).

(8) Starting with the bolts marked “P” on the cover

first, tighten clutch cover bolts in a star pattern to 50

N·m torque (37 ft. lbs.).

(9) Apply light coat of Mopar

high temperature

bearing grease to pilot bearing and splines of trans-

mission input shaft.

Fig. 3 Clutch Disc Position

1 – INSPECT THIS SURFACE

2 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE

CAUTION: Do not over-lubricate as this will result

in grease contamination of the disc.

CLUTCH

6 - 3

REMOVAL AND INSTALLATION (Continued)

PILOT BEARING

REMOVAL

(1) Remove the transmission and transfer case.

Refer to Group 21, Transmission and Transfer Case

for procedures.

Fig. 4 Clutch Disc Alignment – Typical

1 – FLYWHEEL

2 – CLUTCH COVER AND DISC

3 – CLUTCH DISC ALIGNMENT TOOL

Fig. 6 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY

2 – ENGINE SPEED SENSOR

3 – PRESSURE PLATE RETAINING BOLTS

4 – CLUTCH COVER (PRESSURE PLATE)

5 – ENGINE OIL PAN

6 – PRESSURE PLATE RETAINING BOLTS

(2) Remove the clutch cover and disc (Fig. 6). Refer

to clutch cover and disc removal and installation in

this group.

(3) Remove

the

four

bolts

that

attach

the

pilot

bearing retainer to the flywheel (Fig. 7).

(4) Remove the pilot bearing retainer.

(5) Support

the

bearing

retainer

two

wood

Fig. 5 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY

2 – ENGINE SPEED SENSOR

3 – PRESSURE PLATE RETAINING BOLTS

4 – CLUTCH COVER (PRESSURE PLATE)

5 – ENGINE OIL PAN

6 – PRESSURE PLATE RETAINING BOLTS

blocks.

(6) Remove the pilot bearing with a suitable sized

socket and extension (Fig. 8). Use mallet to tap bear-

ing out of retainer.

(10) Install the transmission and transfer case.

Refer to Group 21, Transmission and Transfer Case

for procedure.

6 - 4

CLUTCH

REMOVAL AND INSTALLATION (Continued)

Fig. 9 Pilot Bearing Installation

1 – HOUSING

2 – SPECIAL TOOL C-4171

3 – BEARING

Fig. 7 Pilot Bearing Retainer Bolt Removal/

Installation

1 – RETAINER

2 – PILOT BEARING

3 – FLYWHEEL

Fig. 10 Pilot Bearing Seated In Retainer

1 – SEAT PILOT BEARING FLUSH WITH LOWER EDGE OF

CHAMFER (IN BORE)

Fig. 8 Pilot Bearing Removal

1 – HOUSING

2 – SUITABLE SIZE SOCKET

3 – EXTENSION

(1) Lightly scuff sand the flywheel surface with

180 grit emery cloth. Clean the surface with Mopar

brake or carburetor cleaner.

(2) Install the new pilot bearing with hammer and

tool handle C-4171. (Fig. 9). Seat the bearing flush

with lower edge of chamfer in retainer bore (Fig. 10).

Reposition the bearing if necessary.

(3) Install the bearing retainer. Torque bolts to 28

N·m (20 ft. lbs.)

(4) Lubricate the pilot bearing with Mopar

INSTALLATION

CAUTION: The bearing can be installed incorrectly

if care is not exercised. Make sure the stamped let-

ters on the bearing will be facing out (toward rear

of vehicle) after installation.

high

temperature wheel bearing grease.

CLUTCH

6 - 5

REMOVAL AND INSTALLATION (Continued)

Fig. 11 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY

2 – ENGINE SPEED SENSOR

3 – PRESSURE PLATE RETAINING BOLTS

4 – CLUTCH COVER (PRESSURE PLATE)

5 – ENGINE OIL PAN

6 – PRESSURE PLATE RETAINING BOLTS

Fig. 12 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY

2 – ENGINE SPEED SENSOR

3 – PRESSURE PLATE RETAINING BOLTS

4 – CLUTCH COVER (PRESSURE PLATE)

5 – ENGINE OIL PAN

6 – PRESSURE PLATE RETAINING BOLTS

INSPECTION

Examine the flywheel mounting surfaces, clutch

contact surface, and ring gear. Check condition of fly-

wheel hub and attaching bolts. Replace flywheel if

hub exhibits cracks in the area of attaching bolt

holes. Replace ring gear if the teeth are damaged.

Resurface the flywheel if the clutch contact surface is

scored or rough (refer to flywheel finishing and ring

gear replacement information in this section.

Check flywheel runout if misalignment is sus-

pected. Runout should not exceed 0.08 mm. Measure

flywheel face runout with a dial indicator (Fig. 13).

Mount the indicator on a stud installed in the engine

block or in one of the flywheel attaching bolt holes.

Face runout can be corrected by resurfacing if neces-

sary. Surface grinding equipment is recommended for

this purpose. Stock removal should not exceed 0.25

mm.

(5) Install the clutch disc and cover (Fig. 11). Refer

to clutch cover and disc removal and installation in

this group.

(6) Install the transmission and transfer case.

Refer to Group 21, Transmission and Transfer Case

for procedures.

FLYWHEEL

REMOVAL

(1) Remove the transmission and clutch housing.

Refer to Group 21, Transmission and Transfer Case

for procedure.

(2) Remove the clutch cover and disc (Fig. 12) as

described in this section.

(3) Remove

the

bolts

that

attach

pilot

bearing

retainer to flywheel.

(4) Remove the pilot bearing and retainer.

(5) Remove the flywheel bolts.

(6) Grasp the flywheel firmly and work it off the

crankshaft flange.

(7) Remove the o-ring from the crankshaft flange,

or the mounting shoulder of the flywheel (Fig. 14).

(8) Clean the flywheel in solvent.

INSTALLATION

CAUTION: Use NEW flywheel bolts for the following

procedure.

(1) Clean the crankshaft flange before mounting

the flywheel. Dirt or grease on flange surface may

cock flywheel causing run-out.

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