wheel CHRYSLER VOYAGER 2004 Service Manual

izer, do not remove the locking pliers until
reinstallation of the cable is complete.(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 100).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 100). (5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 101). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 101).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
REMOVAL - PARKING BRAKE CABLE (RIGHT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in the rear parking brake cables
by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 102).
(5) Disconnect the right rear parking brake cable
from the connector on the intermediate cable (Fig.
103). (6) To remove the right parking brake cable hous-
ing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers (Fig. 104). The alternate method
using an aircraft type hose clamp will not work on
the right side of the vehicle. (7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
Fig. 100 Parking Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 101 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 102 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RS BRAKES5s-63
CABLES - PARKING BRAKE (Continued)

(8) Disconnect parking brake cable from parking
brake actuator lever. (9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 105).
Remove the cable.
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly. (3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in rear park brake cables by lock-
ing out the automatic adjuster as described here.
Grasp an exposed section of front park brake cable
near the equalizer and pull down on it. Then install
a pair of locking pliers on the cable just rearward of
the second body outrigger bracket (Fig. 106).
(5) Disconnect the left rear parking brake cable
from the parking brake cable equalizer (Fig. 107).
Fig. 103 Right Rear Cable Connection To Intermediate Cable
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 104 Right Park Brake Cable Removal From Body Bracket
1 - RIGHT REAR BODY BRACKET
2 - PARK BRAKE CABLE
3 - 14MM WRENCH
4 - LEAF SPRING AND BRACKET
Fig. 105 Removing Park Brake Cable From Brake Support Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 106 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
5s - 64 BRAKESRS
CABLES - PARKING BRAKE (Continued)

(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 97). (11) Lower vehicle and apply the park brake pedal
1 time. This will seat the parking brake cables.
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets. (2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 100) (Fig. 101). (3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION). (4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 101). (5) Install the intermediate park brake cable on
the cable equalizer (Fig. 100). (6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables. (7) Install and position the foam collar on the
parking brake cable to prevent it from rattling
against the vehicle's floor. (8) Lower the vehicle and apply the park brake
pedal 1 time, this will seat the park brake cables.
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place. (2) Attach the parking brake cable onto the park-
ing brake actuator lever. (3) Install the brake shoes on the rear brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place. (5) Connect the right rear parking brake cable to
the connector on the intermediate parking brake
cable (Fig. 103). (6) Install the brake drum, then the wheel and tire
assembly. (7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables. (8) Lower the vehicle. (9) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place. (2) Attach the parking brake cable onto the park
brake actuator lever. (3) Install the brake shoes on the rear brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place. (5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 107). (6) Install brake drum, and wheel and tire assem-
bly. (7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables. (8) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag. Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. (Refer t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer t o 5 - BRAKES/PARKING
BRAKE/SHOES - ADJUSTMENTS). When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes. When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
5s - 66 BRAKESRS
CABLES - PARKING BRAKE (Continued)

(6) Remove the front parking brake cable housing
from body outrigger bracket. Cable is removable by
sliding a 14 mm box wrench over the cable retainer
and compressing the three retaining fingers. Alter-
nate method: Use an aircraft type hose clamp and
screwdriver. (7) Remove the four mounting nuts from the bot-
tom of the parking brake lever bracket. (8) Lower vehicle.
(9) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL) (10) If equipped with a manual transaxle, remove
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- REMOVAL) (11) Unhook the end of the parking brake cable
from the lever mechanism. (12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers. (13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment. (14) Lift the parking brake lever and slide the
parking brake cable out. (15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle. (2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket. (3) Hook the end of the parking brake cable on the
parking brake lever mechanism. (4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan. (5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION) (6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION) (7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place. (9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place. (10) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 113). (12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables. (13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake. The park-
ing brake is set to keep the hub/bearing and
axle shaft from rotating when loosening the
hub nut. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove the wheel and tire assembly.
(4) AWD only - Remove the cotter pin and nut
retainer (Fig. 114) from the stub shaft of the outer
C/V joint.
Fig. 114 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RS BRAKES5s-69
LEVER - PARKING BRAKE (EXPORT) (Continued)

(16) AWD only - Remove ABS wheel speed sensor
head from hub/bearing (Fig. 123).
(17) FWD only - Remove the ABS wheel speed sen-
sor from the hub/bearing in the following fashion: (a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 124). (b) Push up on metal retaining clip (Fig. 124)
until it bottoms. This will release wheel speed sen-
sor head from hub and bearing. While holding
metal clip up, pull back on wheel speed sensor
head removing it from hub and bearing. (c) Remove wheel speed sensor from hub/bear-
ing. (18) Remove the hub/bearing-to-axle mounting
bolts (Fig. 125).
(19) Remove the hub/bearing (Fig. 126).
Fig. 123 Speed Sensor Attaching Bolt (AWD)
1 - ADAPTER
2 - TONE WHEEL
3 - WHEEL SPEED SENSOR
4 - AXLE
5 - BOLT
6 - DRIVESHAFT
Fig. 124 Sensor Connection At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 125 Hub/Bearing Mounting Bolts (AWD Shown)
1 - DRIVESHAFT
2 - MOUNTING BOLTS
3 - AXLE
4 - MOUNTING BOLTS
5 - ADAPTER
Fig. 126 Hub/Bearing Removal/Installation (AWD Shown)
1 - PARK BRAKE BRAKE SHOE
2 - OUTER C/V JOINT
3 - HUB/BEARING
4 - PARK BRAKE BRAKE SHOE
5 - STUB SHAFT
5s - 72 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(27) Remove the hold down spring and pin (Fig.
134) from the trailing park brake shoe.
(28) Remove the trailing park brake shoe from the
adapter. (29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (3) Install the hold down spring and pin (Fig. 134)
on the trailing park brake shoe. (4) Install the upper return springs (Fig. 133) on
the trailing park brake shoe. (5) Install the upper return springs on the leading
park brake shoe (Fig. 132). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter. (6) Install the adjuster (Fig. 131) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (7) Install the hold down spring and pin (Fig. 130)
on the leading park brake shoe. (8) Install the lower return spring (Fig. 129) on
the leading and trailing park brake shoes. When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 129). (9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle. (10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 135).
(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 126). (12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.). (13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 123). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs). (14) FWD only - Install the wheel speed sensor in
the following fashion: (a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
Fig. 134 Trailing Brake Shoe Hold Down Pin And Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
Fig. 135 Adapter Installed On Mounting Bolts (AWD Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
RS BRAKES5s-75
SHOES - PARKING BRAKE (Continued)

(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.
(15) Install the park brake cable into its mounting
hole in the adapter. Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter. (16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 121). (17) Attach park brake cable to adapter using
mounting bolt. (18) Remove the locking pliers (Fig. 117) from the
front park brake cable. (19) Adjust the park brake drum-in-hat brake
shoes. (Refer t o 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS). (20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 119).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 118).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.). (23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 116) on the stub shaft of
the outer C/V joint. (24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.). (26) AWD only - Install the spring washer (Fig.
115) on the stub shaft of the outer C/V joint. (27) AWD only - Install the nut retainer and cotter
pin (Fig. 114) on the stub shaft of the outer C/V joint. (28) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.). (29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum. (5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent, accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
137). (6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 138).
Fig. 136 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 76 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 139). (8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes. (9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool. (10) Repeat step 8 above and measure shoes in
both directions. (11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum. (13) Install disc brake caliper on caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION). (14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 135 N´m (100 ft. lbs.). (16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
Fig. 137 Measuring Park Brake Drum Diameter
Fig. 138 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 139 Setting Gauge To Park Brake Shoe Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
RS BRAKES5s-77
SHOES - PARKING BRAKE (Continued)

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM.............................3
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT.......................6
DIAGNOSIS AND TESTING - CLUTCH
COVER AND DISC RUNOUT..............6
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS.................6
SPECIAL TOOLS - T850 TRANSAXLE........6
CLUTCH RELEASE LEVER AND BEARING
REMOVAL.............................6
INSTALLATION..........................7
MASTER CYLINDER - RHD
REMOVAL.............................8
INSTALLATION..........................9
MASTER CYLINDER - LHD
REMOVAL.............................9INSTALLATION.........................10
MODULAR CLUTCH ASSY - 2.4L GAS
REMOVAL.............................11
INSTALLATION.........................11
SLAVE CYLINDER
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH DISC AND PRESSURE PLATE - 2.5L TD
REMOVAL.............................11
INSTALLATION.........................12
FLYWHEEL
REMOVAL.............................12
INSTALLATION.........................12
CLUTCH PEDAL INTERLOCK SWITCH
REMOVAL.............................13
INSTALLATION.........................14
CLUTCH PEDAL UPSTOP SWITCH
REMOVAL.............................15
INSTALLATION.........................16
CLUTCH
DESCRIPTION
CLUTCH COMPONENTS
Models equipped with a 2.4L Gas engine utilize a
modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.
Models equipped with the 2.5L Turbo Diesel engine
utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it ishighly
recommended that the clutch cover and disc be
replaced as a set.
Fig. 1 Modular Clutch AssemblyÐ2.4L Gas Engines
1 - MODULAR CLUTCH ASSEMBLY
RSCLUTCH6-1

Fig. 2 Clutch Disc and Pressure PlateÐ2.5L TD Engines
1 - FLYWHEEL
2 - DISC
3 - PRESSURE PLATE
6 - 2 CLUTCHRS
CLUTCH (Continued)