service CHRYSLER VOYAGER 1996 Service Manual

Upon application of the brake pedal, the lever
should move down, turning the star wheel. A definite
rotation of the star wheel should be seen if the auto-
matic adjuster is working properly. If no rotation of
the star wheel is observed when the pedal is consec-
utively pressed and released, the respective drum
will have to be removed and the adjuster serviced.
MASTER CYLINDER FLUID LEVEL CHECK
The master cylinder used in this vehicle has the
same fluid level markings as the master cylinders
used in other brake systems on the side of the fluid
resevoir. Refer to the Master Cylinder Fluid Level
Check in the Diagnosis and Testing section of group
5 for more information
REMOVAL AND INSTALLATION
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance group of this service manual.
(2) Remove the intermediate and left rear park
brake cable from the park brake cable equalizer (Fig.
2).
(3) Remove the front park cable housing retainer
from body outrigger bracket (Fig. 3). Cable is remov-
able by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.(4) Remove the two (2) retaining nuts and (2)
retaining bolts from the bottom of the parking brake/
gearshift lever bracket.
(5) Lower vehicle.
(6) Carefully lift the base of the gearshift boot
from the gearshift console to access the screws (Fig.
4).
Fig. 2 Park Brake Cable Attachment To Equalizer
Fig. 3 Front Park Brake Cable Attachment To Body
Fig. 4 Console and Gearshift boot
5 - 2 BRAKESNS/GS
DIAGNOSIS AND TESTING (Continued)

CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS.................. 1
CLUTCH DISC AND COVER APPLICATION . . . 3
CLUTCH REPLACEMENT................. 3
DESCRIPTION AND OPERATION
CLUTCH PEDAL POSITION SWITCH........ 4
CLUTCH RELEASE SYSTEM.............. 4
DIAGNOSIS AND TESTING
CLASH±INTO±REVERSE
COMPLAINTS........................ 8
CLUTCH CHATTER COMPLAINTS.......... 8
CLUTCH COVER AND DISC RUNOUT....... 8
CLUTCH DIAGNOSIS.................... 6
CLUTCH PEDAL POSITION SWITCH........ 4
DRIVE PLATE MISALIGNMENT............ 7
REMOVAL AND INSTALLATION
CLUTCH ASSEMBLY (2.5L DIESEL)....... 13
CLUTCH CABLE SYSTEM Ð LHD.......... 8
CLUTCH PEDAL POSITION SWITCH....... 10CLUTCH RELEASE BEARING AND FORK . . . 14
HYDRAULIC CLUTCH LINKAGE SYSTEM Ð
RHD ............................... 11
MASTER CYLINDER SYSTEM
Ð RHD ............................ 12
MODULAR CLUTCH ASSEMBLY (2.0L AND
2.4L GASOLINE)..................... 13
QUICK CONNECT COUPLING
Ð RHD ............................ 12
SLAVE CYLINDER ASSEMBLY
Ð RHD ............................ 12
CLEANING AND INSPECTION
CLEANING PRECAUTIONS............... 15
CLUTCH CONTAMINATION.............. 15
ADJUSTMENTS
CLUTCH CABLE Ð LHD................ 16
CLUTCH PEDAL POSITION SWITCH....... 16
SPECIFICATIONS
CLUTCH TIGHTENING REFERENCE........ 16
GENERAL INFORMATION
CLUTCH COMPONENTS
The clutch used in the 2.0 liter and 2.4 liter gaso-
line engine is a single, dry-disc modular clutch
assembly. The modular clutch assembly combines the
pressure plate cover, pressure plate, disc, and fly-
wheel into one unit. The unit rides on the input shaft
of the transmission and is bolted to the drive plate
mounted on the rear of the crankshaft. The clutch
used in the 2.5 liter diesel engine is a conventional
clutch and pressure plate arrangement.
CLUTCH CABLE AND PEDAL Ð LHD
The clutch cable has a unique self-adjuster mecha-
nism built into the cable which compensates for
clutch disc wear. The cable requires no maintenance
or lubrication. There are no serviceable components
on the cable assembly.The clutch pedal is connected to the cable through
a plastic spacer (Fig. 1). The upper end of the clutch
pedal pivots in the pedal bracket on two nylon bush-
ings and a shaft (Fig. 2). These bushings are greased
during assembly and do not require periodic lubrica-
tion.
Fig. 1 Upstop/Spacer and Cable Ð LHD
NS/GSCLUTCH 6 - 1

The clutch pedal on the 2.0L is fitted with a return
spring (Fig. 3). The spring hook that attaches to the
pedal is coated with nylon. Push the hook all the way
through the hole in the pedal to prevent it from
walking out. No service lubrication is required.
The clutch pedal on the 2.4L and 2.5L VM diesel is
fitted with an assist spring (Fig. 4) to reduce clutch
pedal effort. The assist spring has two plastic end fit-
tings which locate to pins on the clutch pedal and
bracket. The plastic which the fittings are made of
includes PTFE lubricant. No service lubrication is
required.
HYDRAULIC LINKAGE AND COMPONENTS Ð
RHD
The hydraulic clutch linkage is a prefilled system
free of air, contamination, and leaks. There is no rou-
tine maintenance required. The hydraulic clutch link-
age is serviced as an assembly and the individual
components cannot be overhauled or serviced sepa-
rately. The hydraulic linkage consists of a clutch
master cylinder with integral reservoir, a clutch slave
cylinder and an interconnecting fluid line with quick
disconnect coupling (Fig. 5).
The clutch master cylinder push rod is connected
to the clutch pedal (Fig. 6). The clutch pedal is fitted
with a return spring. The spring hook that attaches
to the pedal is coated with nylon. No service lubrica-
tion is necessary. The slave cylinder push rod is con-
nected to the clutch release fork (Fig. 5).
Fig. 2 Clutch Pedal Components Ð LHD
Fig. 3 Clutch Pedal Return Spring Ð 2.0L LHD
Fig. 4 Assist Spring Ð 2.4L and 2.5L VM Diesel LHD
6 - 2 CLUTCHNS/GS
GENERAL INFORMATION (Continued)

CLUTCH DISC AND COVER APPLICATION
The 2.0 liter and 2.4 liter gasoline engines use a
240 mm (9.5 in.) modular clutch assembly. The 2.5
liter diesel engine uses a 240 mm (9.5 in.) standard
clutch and pressure plate arrangement. Although the
clutches are the same size they do not interchange.
CLUTCH REPLACEMENT
The transaxle must be removed to service the
clutch assembly, fork, or bearing.
Fig. 5 Hydraulic Clutch Linkage System Ð RHD
Fig. 6 Clutch Master Cylinder Mounting Ð RHD
NS/GSCLUTCH 6 - 3
GENERAL INFORMATION (Continued)

the switch is in its normal (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050), the ohmmeter should show continuity (zero
ohms).
If ohmmeter readings do not fall within these
ranges, the switch is defective, and must be replaced.
CLUTCH PEDAL POSITION
SWITCH±MECHANICAL TEST
With the park brake set and the vehicleIN NEU-
TRAL,turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is
defective (shorted out) and must be replaced. If the
vehicle does not crank proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.With the park brake set and the vehicleIN GEAR,
turn the key to the start position and hold it there.
Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there
is no motion the switch is working properly.
If motion is felt, check to see if the switch is mak-
ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch or
the clutch actuation system (See ªClutch Will Not
Disengage Properlyº). If this condition is not met,
then the switch mounting tab on the brake bracket is
bent, and the brake bracket must be replaced.
If vehicle will not crank, even with clutch pedal
pressed to the floor, refer to ªService Diagnosis-
Clutch Pedal Position Switchº chart in this section.
SERVICE DIAGNOSIS±CLUTCH PEDAL POSITION SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WON'T CRANK WHEN
CLUTCH PEDAL IS PRESSED TO
THE FLOORSwitch does not have continuity
when plunger is depressed 1.25 mmDefective switch. Replace switch.
Switch plunger is not depressed
when clutch pedal is pushed to the
floorFloor mat interferes with clutch pedal
movement. Move floor mat out of the
way.
Switch mounting bracket is bent.
Replace brake bracket assembly
Problem is related to other
components in the starting circuitCheck other components in the
starting circuit. Refer to Section 8A,
Battery/Starting/Charging System.
NS/GSCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)

CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road
test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges andobserve clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSIS±CLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or transaxle
input shaft sealCorrect leak and replace clutch assembly
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to suspension
or driveline componentFurther diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release fingers
bent, distorted (rough handling, improper
assembly)Replace clutch assembly
Clutch disc damaged or distorted Replace clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for
damage. Correct as necessary.
SERVICE DIAGNOSIS±CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN
OUTNormal wear. Replace clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear overheating.Replace clutch assembly
Insufficient clutch cover diaphragm
spring tensionReplace clutch assembly
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASELeak at rear main oil seal or transaxle
input shaft sealReplace leaking seals. Replace clutch
assembly.
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY
DISENGAGEDRelease bearing sticking or binding,
does not return to normal running
position.Verify that bearing is actually binding.
Then, replace bearing and transmission
front bearing retainer if sleeve surface is
damaged.
Cable self-adjuster mechanism sticking
or binding causing high preload (LHD
Applications only)Verify that self-adjuster is free to move
(LHD Applications only)
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECESDriver performs a 5-1 downshift at
vehicle speed in excess of 60 miles per
hourAlert driver to problem cause. Replace
clutch assembly.
Excessive heat from slippage Replace clutch assembly
6 - 6 CLUTCHNS/GS
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSIS±IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINESClutch disc hub splines damaged during
installationClean, smooth, and lubricate disc and
shaft splines. Replace clutch assembly
and/or input shaft if splines are severely
damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on splines
of input shaft and discClean input shaft splines and disc
splines, then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATEOccurs in vehicles stored or not driven
for extended period of time. Also occurs
after steam cleaning if vehicle is not
used for extended period.Replace clutch assembly
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace clutch assembly
Clutch cover diaphragm spring damaged
during transaxle installationReplace clutch assembly
Release fork and (or) bushings
damagedReplace fork and (or) bushings if worn or
damaged
Clutch cable binding or routed
incorrectlyCheck and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable slackPull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
Clutch pedal travel restricted Verify clutch pedal can travel all the way
to the downstop on the bracket
SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL MAKES
REPEATED9POP9NOISE
IN THE FIRST INCH OF
TRAVELSelf-adjusting mechanism in cable
defective (LHD Applications)Replace clutch cable (LHD Applications)
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOORPedal bushings worn out or inadequate
lubricationReplace or lubricate bushings
Clutch pedal assist spring fittings worn
outReplace assist spring fittings
Clutch release shaft bushings in the
bellhousing are worn outReplace release shaft and bushings
DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft boltsClean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
NS/GSCLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)

HYDRAULIC CLUTCH LINKAGE SYSTEM Ð RHD
CAUTION: Do not actuate the master cylinder or
step on the clutch pedal before the quick connect
coupling is joined or an over pressure condition
could result in damage to the master cylinder, the
quick connect coupling, or the dash panel.
NOTE: The hydraulic clutch linkage system is pre-
filled by the supplier who warrants the system to be
free of air, contamination, and leaks. No routine
maintenance is required. Except for the self-retain-
ing snap-on master cylinder pushrod bushing, the
hydraulic system is serviced only as a complete
assembly and individual components cannot be
overhauled or replaced.
REMOVAL
1. Disconnect the quick connect coupling to facili-
tate the removal of the master cylinder assembly and
slave cylinder assembly separately (Fig. 14). Refer to
the removal and installation procedure in this section
for detailed instructions on disconnecting and con-
necting the quick connect coupling.
2. Remove the master cylinder assembly (Fig. 15).
Refer to the master cylinder removal and installation
procedure in this section for detailed instructions on
removal of the master cylinder assembly.3. Remove the slave cylinder assembly. Refer to
the slave cylinder removal and installation procedure
in this section for detailed instructions on removal
and installation of the slave cylinder.
INSTALLATION
1. For installation of the hydraulic clutch linkage
system, reverse the above procedure.
Fig. 14 Hydraulic Clutch Linkage System Ð RHD
Fig. 15 Self-Retaining Snap-on Bushing Ð RHD
NS/GSCLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
1. Position the slave cylinder assembly to the tran-
saxle deck and secure with the nut and washer
assemblies (2) and tighten to specifications (Fig. 14).
2. Make sure the slave cylinder pushrod is prop-
erly seated in the cup end of the clutch release lever.
3. Connect the quick connect coupling. Refer to the
ªQuick Connect Couplingº removal and installation
procedure in this section.
MODULAR CLUTCH ASSEMBLY (2.0L AND 2.4L
GASOLINE)
The transaxle must be removed to service the mod-
ular clutch assembly and components (Fig. 17). Refer
to Group 21 for the ªA-558 Manual Transaxleº
removal procedure.
CLUTCH ASSEMBLY (2.5L DIESEL)
The transaxle must be removed to service the
clutch disc assembly and components.
REMOVAL
(1) Remove the transaxle, refer to Group 21, Tran-
saxle.
(2) Install universal clutch alignment tool into the
clutch assembly (this will prevent the clutch from
inadvertently being dropped).
(3) To avoid distortion of the pressure plate,
remove the clutch pressure plate bolts a few turns at
a time. Use a crisscross pattern until all bolts are
loosened.
(4) Carefully remove the clutch pressure plate and
disc (Fig. 18).To service the flywheel, refer to Group 9, Engine.
INSPECTION
Inspect for oil leakage through engine rear main
bearing oil seal and transaxle input shaft seal. If
leakage is noted, it should be corrected at this time.
The friction faces of the flywheel and pressure
plate should not have:
²Excessive discoloration
²Burned areas
²Small cracks
²Deep grooves
²Ridges
Replace parts as required.
CAUTION: Do not polish flywheel to a mirror like
surface. Clean the flywheel face with medium sand-
paper (80-160 grade), then wipe the surface with
mineral spirits. If the surface is severely scored,
heat checked, or warped, replace the flywheel.
CAUTION: Do not flat-machine the flywheel face.
The surface profile is slightly tapered and has a
0.30 mm step.
The disc assembly should be handled without
touching the facings. Replace disc if the facings show
evidence of grease or oil soakage, or wear to within
less than .38 mm (.015 inch) of the rivet heads. The
splines on the disc hub and transaxle input shaft
should be a snug fit without signs of excessive wear.
Metallic portions of disc assembly should be dry and
clean, and not been discolored from excessive heat.
Each of the arched springs between the facings
should not be broken and all rivets should be tight.
Wipe the friction surface of the pressure plate with
mineral spirits.
Using a straight edge, check clutch cover (pressure
plate) for flatness. The clutch cover (pressure plate)
Fig. 17 Modular Clutch Assembly Ð 2.0L and 2.4L
Fig. 18 Clutch Disc, Cover and Pressure Plate
NS/GSCLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)

(3) Remove the fork from the bearing thrust plate
(Fig. 22).
(4) Examine the condition of the bearing. It is pre-
lubricated and sealed and should not be immersed in
oil or solvent.
(5) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(6) The bearing has a plastic sleeve pre-lubricated
at assembly. Wipe out the old grease. Refill the sleeve
cavities and coat the inner surface with multipurpose
grease. If the liner is cracked or worn, replace the
bearing assembly.
(7) Check the condition of the spring clips. If the
clips are broken or distorted, replace the bearing
assembly.
INSTALLATION
(1) Before assembling the fork, lubricate the
rounded thrust pads and the spring clip cavities with
multipurpose grease.
(2) Assemble the fork to the bearing by sliding the
thrust pads under the spring clips. Be careful to
avoid distorting the spring clips. These clips prevent
the bearing thrust plate from rotating with the bear-
ing.
(3) Slide the bearing and fork assembly onto the
input shaft bearing retainer.
(4) Position the release shaft bushings in the hous-
ing and install the release shaft. A small amount of
bearing grease between the release shaft bushing
and the shaft is beneficial but not required. Install
the retainer clip in the shaft groove near the large
bushing.
(5) Install the release lever and retaining clip on
the outer end of the release shaft.
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty opera-
tion.
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, or water/
road splash on clutch components.
OIL CONTAMINATION
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 CONTAMINATION
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, contami-
nating the disc.
ROAD SPLASH/WATER CONTAMINATION
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 tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
CLEANING PRECAUTIONS
Condensation from steam vapors tend to accumu-
late on the internal clutch mechanism when the vehi-
cle is steam cleaned. Facing of disc will absorb
moisture and will bond to flywheel and/or pressure
plate, if vehicle is allowed to stand for some time
before use. If this condition occurs, it may require
replacement of clutch assembly. After cleaning, drive
the vehicle to its normal clutch operating tempera-
ture. This will dry off disc assembly, pressure plate,
and flywheel.
Fig. 22 Clutch Release Fork
NS/GSCLUTCH 6 - 15
REMOVAL AND INSTALLATION (Continued)