clutch CHRYSLER CARAVAN 2002 Service Manual

5TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fifth gear is pressed on to the input shaft,
and is in constant mesh with the intermediate shaft
fifth speed gear. Because of this constant mesh, the
intermediate shaft fifth speed gear freewheels until
fifth gear is selected. As the gearshift lever is moved
to the fifth gear position, the 5-R fork moves the 5-R
synchronizer sleeve towards the intermediate shaft
fifth speed gear. The synchronizer sleeve engages the
fifth gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 8).
Fig. 8 5th Gear Operation
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REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reverse
gear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
Fig. 9 Reverse Gear Operation
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DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Hard shifting may also be caused by a binding or
broken shift cover mechanism. Remove shift cover
and verify smooth operation. Replace as necessary.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, keys, balls, or springs can cause shift prob-
lems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement. Check
for missing snap rings.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
REMOVAL - 2.4L GAS
(1) Raise hood.
(2) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 10).
(3) Remove gearshift cable retaining clips from
mounting bracket (Fig. 10). Remove cables and
secure out of way.
(4) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 11).
(5) Raise vehicle on hoist.
(6) Remove front wheel/tires and halfshafts.
(7) Drain transaxle fluid into suitable container.
(8) Remove front harness retainer and secure har-
ness out of way.
Fig. 10 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
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(9) Using Tool 6638A, disconnect clutch hydraulic
circuit quick connect (located on slave cylinder tube).
Remove clutch slave cylinder by depressing towards
case and rotating counter-clockwise 60É, while lifting
anti-rotation tab out of case slot with screwdriver
(Fig. 12).
(10) Remove engine left mount bracket.
(11) Remove starter motor (Fig. 13).
(12) Disconnect back-up lamp switch connector.
(13) Remove structural collar.
(14) Remove modular clutch assembly-to-drive
plate bolts.
(15) Position screw jack and wood block to engine
oil pan.
(16) Remove transmission upper mount through-
bolt from left frame rail.
(17) Lower engine/transaxle assembly on screw
jack.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
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(18) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 14).
(19) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(20) Remove transaxle from engine.
(21) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
REMOVAL - 2.5L TD
(1) Raise hood.
(2) Disconnect both battery cables.
(3) Remove battery thermal shield (Fig. 15).
(4) Remove battery hold down bolt, clamp, and
battery (Fig. 16).
Fig. 14 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
Fig. 15 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 16 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
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(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove front harness retainer and secure
harness out of way.
(16) Using Tool 6638A, disconnect clutch hydrau-
lic circuit quick connect (located on slave cylinder
tube). Remove clutch slave cylinder by depressing
towards case and rotating counter-clockwise 60É,
while lifting anti-rotation tab out of case slot with
screwdriver (Fig. 21).
(17) Remove engine left mount bracket (Fig. 22).
(18) Remove starter motor (Fig. 23).
(19) Disconnect back-up lamp switch connector.
(20) Position screw jack and wood block to engine
oil pan.
(21) Remove transmission upper mount through-
bolt from left frame rail.
(22) Lower engine/transaxle assembly on screw
jack.
Fig. 21 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 22 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
Fig. 23 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
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(23) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 24).
(24) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(25) Remove transaxle from engine (Fig. 25).
(26) Inspect clutch, clutch release components, and
flywheel.DISASSEMBLY
(1) Remove clutch release lever and bearing (Fig.
26). Inspect release lever pivot balls and replace if
necessary (Fig. 27). Use slide hammer C-3752 and
remover/installer 6891 (Fig. 28) if pivot ball replace-
ment is necessary.
Fig. 25 Transaxle Removal/Installation
1 - TRANSAXLE
2 - BOLT
Fig. 24 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
Fig. 26 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
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(32) If previously removed, install clutch release
lever pivot ball(s) using slide hammer C-3752 and
remover/installer 6891 (Fig. 74) (Fig. 75).(33) Install clutch release bearing to lever. Apply
grease to interface (contact) points. Make sure
release bearing retainers engage lever pocket as
shown in (Fig. 76).
(34) Apply grease to pivot ball(s), and on release
lever at slave cylinder contact point.
(35) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball (Fig. 77). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
Fig. 74 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 75 Pivot Ball Position
1 - PIVOT BALL (1)
Fig. 76 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
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INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
(8) Install starter motor into position (Fig. 78).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 79). While
depressing inward, rotate slave cylinder clockwise
60tÉ into position until nylon locating tab rests
within transaxle case cutout, and hydraulic tube is
vertical. Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
Fig. 77 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 78 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 79 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
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INSTALLATION - 2.5L TD
(1) Assemble transaxle to engine, while aligning
transaxle input shaft to clutch disc splines.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.) (Fig. 82).
(3) Install transaxle upper mount (Fig. 83). Install
and torque four (4) mount-to-transaxle bolts to 54
N´m (40 ft. lbs.).
(4) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(5) Remove screw jack.
(6) Connect back-up lamp switch connector.
Fig. 82 Transaxle Removal/Installation
1 - TRANSAXLE
2 - BOLT
Fig. 83 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
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