clutch CHRYSLER VOYAGER 1996 Service Manual

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension
5Brakes
6Clutch
7Cooling System
8ABattery
8BStarting System
8EInstrument Panel and Systems
8HVehicle Speed Control System
8KWiper and Washer Systems
8LLamps
8QVehicle Theft/Security Systems
8UChime Warning/Reminder System
8WWiring Diagrams
9Engine
13Frame and Bumpers
14Fuel SystemÐ2.5L Diesel Engine/2.0L Gas Engine
19Steering
21AÐ598 Manual Transaxle
23Body
24Heating and Air Conditioning
25Emission Control System

²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD powertransfer fluid unit.
18,000 Miles (29 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
21,000 Miles (34 000 km)
²Change engine oil.
²Check AWD overrunning clutch and rear carrier
fluid.
24,000 Miles (38 000 km)
²Change engine oil.
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Inspect brake linings.
²Change AWD power transfer unit fluid.
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve, replace if necessary. *
²Inspect serpentine drive belt, replace if neces-
sary.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
63,000 Miles (101 000 km)
²Change engine oil.
²Change AWD overrunning clutch and rear car-
rier fluid.
²Inspect brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
NSLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

²Replace spark plugs.
²Replace ignition cables.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transaxle fluid and
replace filter. Adjust band, if so equipped. (See note)
²Change AWD power transfer unit fluid.
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
87,000 Miles (139 000 km)
²Change engine oil.
90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect brake linings.
102,000 Miles (163 000 km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and filter. Adjust bands, if so equipped. (See note)
²Change AWD power transfer unit fluid.
²Change AWD overrunning clutch and rear car-
rier fluid.
108,000 Miles (173 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
111,000 Miles (178 000 km)
²Change engine oil.
²Flush and replace engine coolant.
114,000 Miles (182 000 km)
²Change engine oil.
²Replace engine oil filter.
117,000 Miles (187 000 km)
²Change engine oil.
²Inspect brake linings.
120,000 Miles (192 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped.
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90ÉF (32ÉC), using
vehicle for police, taxi, limousine type operation or
trailer towing require the more frequent transaxle
service noted in Schedule ± B. Perform these ser-
vices if vehicle is usually operated under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (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)

DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear (Fig. 7). This adjuster mechanism is
located within the clutch cable assembly. The preload
spring maintains tension on the cable. This tension
keeps the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
HYDRAULIC CLUTCH Ð RHD
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage to disengage and engage the modular clutch
assembly.
The modular clutch assembly contains the cover,
diaphragm spring, pressure plate, disc and flywheel
in one unit. The modular clutch also uses a drive
plate and is bolted to and driven by the drive plate.
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
push rod is connected to the release lever in the
clutch housing.
Depressing the clutch pedal develops fluid pressure
in the clutch master cylinder. This pressure is trans-
mitted to the slave cylinder through a connecting
line. In turn, the slave cylinder operates the clutch
release lever.
The clutch release bearing is mounted on the
transmission front bearing retainer. The bearing is
attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and not driven at this point.
The process of clutch engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 8).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
Fig. 7 Clutch Cable Ð LHD
Fig. 8 Clutch Pedal Position Switch and
Components Ð LHD Shown
6 - 4 CLUTCHNS/GS

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)