DODGE RAM 1500 1998 2.G Workshop Manual

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING.............................1
DIAGNOSIS AND TESTING................1
SPECIFICATIONS........................5
CLUTCH DISC
REMOVAL.............................5
INSTALLATION..........................5
CLUTCH HOUSING
DIAGNOSIS AND TESTING................7
REMOVAL.............................9
INSTALLATION..........................9
CLUTCH RELEASE BEARING
REMOVAL.............................9
INSTALLATION.........................10
FLYWHEEL
DIAGNOSIS AND TESTING................10REMOVAL.............................11
DISASSEMBLY.........................11
ASSEMBLY............................11
INSTALLATION.........................11
PILOT BEARING
REMOVAL.............................11
INSTALLATION.........................12
LINKAGE
REMOVAL.............................12
INSTALLATION.........................12
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING................13
CLUTCH
WARNING
WARNING: Exercise care when servicing clutch
components. Factory installed clutch discs do not
contain asbestos fibers. Dust and dirt on clutch
parts may contain asbestos fibers from aftermarket
components. Breathing excessive concentrations of
these fibers can cause serious bodily harm. Wear a
respirator during service and never clean clutch
components with compressed air or with a dry
brush. Either clean the components with water
dampened rags or use a vacuum cleaner specifi-
cally designed to remove asbestos fibers and dust.
Do not create dust by sanding a clutch discs.
Replace the disc if the friction material is damaged.
Dispose of all dust and dirt containing asbestos
fibers in sealed bags or containers. This will mini-
mize exposure to yourself and to others. Follow all
recommended safety practices prescribed by the
occupational safety and health administration
(OSHA) and the environmental safety agency (EPA),
for the handling and disposal of products contain-
ing asbestos. Failure to follow these instructions
may result in personal injury or death
DIAGNOSIS AND TESTING
Road test and inspect components to determine a
clutch problem. Road test the vehicle at normalspeeds. Shift the transmission through all gear
ranges and observe clutch action. If clutch chatters,
grabs, slips or does not release properly, remove and
inspect clutch components. If problem is noise or
hard shifting, further diagnosis may be needed to the
transmission and driveline component.
CLUTCH CONTAMINATION
Contamination is a frequent cause of clutch mal-
functions. Oil, water or clutch fluid on the clutch disc
and pressure plate surfaces will cause chatter, slip
and grab. Oil contamination indicates a leak at
either the rear main seal or transmission input shaft.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals. Heat buildup caused by slip-
page between the pressure plate, disc and flywheel
can bake the oil residue onto the components. The
glaze-like residue ranges in color from amber to
black.
Road splash contamination is dirt/water entering
the clutch housing due to loose bolts, housing cracks.
Driving through deep water puddles can force water/
road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems can be
caused by worn or damage clutch components.
Release problems can cause hard shifting and
noise. Look for leaks at clutch cylinders, connecting
line and loose slave cylinder bolts. Also worn/loose
release fork, pivot stud, clutch disc, pressure plate or
release bearing.
DRCLUTCH 6 - 1

Engagement problems can cause slip, chatter/shud-
der and noisy operation. The causes may be clutch
disc contamination, wear, distortion or flywheel dam-
age.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
CLUTCH COVER AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of anewdisc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain
another disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with turning equipment. Remove only
enough material to reduce scoring (approximately
0.001 - 0.003 in.). Heavy stock removal isnot rec-
ommended.Replace the flywheel if scoring is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken the fly-
wheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.3. Replace cover and disc.
6 - 2 CLUTCHDR
CLUTCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.1. Release bearing sticking or
binding and does not return to the
normal running position.1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.1. Rough handling. Impact bent
cover, spring, or disc.1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.1. Flywheel surface scored or
nicked.1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.1. Frequent operation under high
loads or hard acceleration
conditions.1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.1. Clutch disc hub splines damaged
during installation.1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
DRCLUTCH 6 - 3
CLUTCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Pilot bearing seized, loose, or rollers
are worn.1. Bearing cocked during
installation.1. Install a new bearing.
2. Bearing defective. 2. Install a new bearing.
3. Bearing not lubricated. 3. Install a new bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low hydraulic linkage fluid level. 1. Add hydraulic linkage fluid.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.7. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.3. Replace and lubricate bushings.
4. Rough surface on front bearing
retainer.4. Replace front bearing retainer.
Clutch master or slave cylinder
plunger dragging andùr binding1. Master or slave cylinder
components worn or corroded.1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.1. Replace release bearing.
Contact surface of release bearing
damaged.1. Clutch cover incorrect or release
fingers bent or distorted.1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
6 - 4 CLUTCHDR
CLUTCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.1. Clutch pressure plate position
incorrect.1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andùr
clutch housing. Correct as
necessary.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Slave Cylinder Nuts 23 17 -
Clutch Master Cylinder
Nuts28 21 -
Pressure Plate Bolts - V6
&V850 37 -
Pressure Plate Bolts - V10 30 22.5 -
Pressure Plate Bolts -
Diesel30 22.5 -
Release Bearing Pivot 23 17 -
Flywheel Bolts 95 70 -
CLUTCH DISC
REMOVAL
(1) Support engine with wood block and adjustable
jack stand, to prevent strain on engine mounts.
(2) Remove transmission and transfer case, if
equipped.
(3) If pressure plate will be reused, mark the posi-
tion on flywheel with paint or scriber (Fig. 1). Also
note location marks on the pressure next to the bolt
holes. The mark will be a L or a circle with an X in
it.
(4) Insert clutch alignment tool through clutch disc
and into pilot bushing, to hold disc in place while
removing bolts.
(5) Loosen pressure plate bolts evenly, a few
threads at a time and in a diagonal pattern to pre-
vent warping the plate.
(6) Remove bolts completely and remove pressure
plate, disc and alignment tool.
INSTALLATION
(1) Check runout and free operation of new clutch
disc.
(2) Lubricate crankshaft pilot bearing with a NLGI
- 2 rated grease.
(3) Install clutch alignment tool in clutch disc hub
with the raised side of hub is facing away from the
flywheel.
NOTE: Flywheel side is imprinted on the disc face.
(4) Install alignment tool in pilot bearing and posi-
tion disc on the flywheel.
(5) Position pressure plate over disc and onto the
flywheel (Fig. 2).
(6) Align and hold pressure plate in position and
install bolts finger tight.
(7) Tighten bolts evenly and a few threads at a
time in a diagonal pattern.
CAUTION: Bolts must be tightened evenly and to
specified torque to avoid warping pressure plate
cover.
DRCLUTCH 6 - 5
CLUTCH (Continued)

(8) Tighten pressure plate bolts to:
²V6 & V8 Engines - 50 N´m (37 ft. lbs.)
²V10 & Diesel Engines - 30 N´m (22.5 ft. lbs.)
(9) Remove release lever and release bearing from
clutch housing. Apply Mopar high temperature bear-
ing grease to bore of release bearing, release lever
contact surfaces and release lever pivot stud (Fig. 3).
(10) Apply light coat of Mopar high temperature
bearing grease to splines of transmission input shaft
and to release bearing slide surface of the transmis-
sion front bearing retainer (Fig. 4).CAUTION: Do not over lubricate shaft splines. This
can result in grease contamination of the disc.
Fig. 1 PRESSURE PLATE POSITION-TYPICAL
1 - FLYWHEEL
2 - ALIGNMENT MARKS
3 - PRESSURE PLATE
Fig. 2 CLUTCH DISC AND PRESSURE PLATE
1 - FLYWHEEL
2 - PRESSURE PLATE AND DISC
3 - ALIGNMENT TOOL
Fig. 3 LUBRICATION POINTS
1 - CLUTCH HOUSING
2 - FORK PIVOT BALL
3 - RELEASE FORK
4 - RELEASE BEARING BORE
5 - LUBE POINTS
Fig. 4 INPUT SHAFT LUBRICATION POINTS
1 - INPUT SHAFT
2 - BEARING RETAINER
3 - SPLINE AND RELEASE BEARING SURFACE
6 - 6 CLUTCHDR
CLUTCH DISC (Continued)

(11) Wipe pilot bearing surface clean.
(12) Install release lever and bearing in clutch
housing. Verify spring clips that retain fork on pivot
ball and release bearing on fork are installed prop-
erly (Fig. 5).
NOTE: If release lever is installed correctly, the
lever part number will be toward the bottom of the
transmission and right side up. There is also a
stamped ªIº in the lever which goes to the pivot ball
side of the transmission.
(13) Install transmission and transfer case if
equipped.
(14) Check fluid level in clutch master cylinder.
CLUTCH HOUSING
DIAGNOSIS AND TESTING
The clutch housing maintains alignment between
the crankshaft and transmission input shaft. Mis-
alignment can cause clutch noise, hard shifting,
incomplete release and chatter. Also premature pilot
bearing, cover release fingers and clutch disc wear.
In severe cases, it can cause premature wear of the
transmission input shaft and front bearing.
NOTE: Only the NV4500 clutch housing can be
checked using the following bore and face runout
procedures. The NV5600 clutch housing is a inte-
gral part of the transmission and can only be
checked off the vehicle.
CLUTCH HOUSING BORE RUNOUT
CAUTION: On diesel engines if housing bore runout
exceeds 0.015 inch, the clutch housing/transmis-
sion adapter plate must be replaced. On gas
engines if housing bore runout exceeds 0.053 in.
the clutch housing must be replaced.
NOTE: Offset dowels are available for gas engines
to correct housing bore runout. They are not avail-
able for diesel engines.
(1) Remove the clutch housing.
(2) Remove the clutch cover and disc.
(3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 6). The rod will be used to mount the dial
indicator.
(4) Remove release fork from the clutch housing.
(5) Install clutch housing. Tighten the housing
bolts nearest the alignment dowels first.
(6) Mount dial indicator on the threaded rod and
position indicator plunger on the clutch housing bore
(Fig. 7).
(7) Rotate crankshaft until indicator plunger is at
the topof the housing bore. Zero the indicator at this
point.
(8) Rotate crankshaft and record indicator read-
ings at eight points (45É apart) around the bore (Fig.
8). Take measurement at least twice for accuracy.
(9) Subtract each reading from the one 180É oppo-
site to determine runout and direction. Bore runout
example (Fig. 8):
²0.000 ± (±0.007) = 0.007 in.
²+0.002 ± (±0.010) = 0.012 in.
²+0.004 ± (±0.005) = 0.009 in.
²±0.001 ± (+0.001) = ±0.002 in.
Fig. 5 FORK, BEARING AND SPRING CLIPS
1 - FORK
2 - SPRING CLIP
3 - BEARING
4 - SPRING CLIP
Fig. 6 DIAL INDICATOR MOUNTING STUD
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
DRCLUTCH 6 - 7
CLUTCH DISC (Continued)

In this example the largest or total indicator read-
ing (TIR) difference is 0.012 inch. This means the
housing bore is offset from the crankshaft centerline
by 0.006 in. which is 1/2 of 0.012 inch. The dowels
needed to correct this have an offset of 0.007 in. (Fig.
9).
Remove housing and install dowels with the slotted
side facing out so they can be turned with a screw-
driver. Then install the housing and mount the dial
indicator and check bore runout again. Rotate the
dowels until the TIR is less than 0.010 inch.
Clutch Housing Face Runout
(1) Position dial indicator towards the housing face
(Fig. 10) with indicator plunger on the rim of the
housing bore.
(2) Rotate crankshaft until indicator plunger is at
the 10 O'clock position and zero the dial indicator.(3) Measure and record face runout readings at
four points 90É apart (Fig. 11). Take measurement at
least twice for accuracy.
(4) Subtract lowest reading from highest to deter-
mine total runout. If low reading wasminus0.004
in. and highest reading wasplus0.009 in. the total
runout is 0.013 inch.
NOTE: Maximum acceptable face runout is 0.010
inch.
Fig. 7 CLUTCH HOUSING BORE RUNOUT
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
Fig. 8 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING BORE CIRCLE
Fig. 9 ALIGNMENT DOWEL SELECTION
1 - SLOT DIRECTION OF OFFSET
2 - OFFSET DOWEL
TIR VALUE OFFSET DOWEL REQUIRED
0.011 - 0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
Fig. 10 DIAL INDICATOR LOCATION
1 - INDICATOR PLUNGER
2 - DIAL INDICATOR
3 - CLUTCH HOUSING FACE
4 - INDICATOR MOUNTING STUD OR ROD
6 - 8 CLUTCHDR
CLUTCH HOUSING (Continued)

To correct this example (Fig. 11) the shims needed
between the clutch housing and transmission are:
²0.009 in. at the 0.000 corner
²0.012 in. at the ±0.003 corner
²0.013 in. at the ±0.004 corner
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow-
els first.
NOTE: Shims can be made from shim stock or sim-
ilar materials of the required thickness (Fig. 12).
REMOVAL
(1) Remove transmission and transfer case (Fig.
13).
(2) Remove starter from clutch housing.
(3) Remove structural dust cover bolts from clutch
housing.
CAUTION: Do not remove structural dust cover
from enigne block. If cover is removed clutch hous-
ing and cover must be aligned with the engine.(4) Remove clutch housing bolts and remove hous-
ing from the engine.
INSTALLATION
(1) Clean housing mounting surface of engine
block with wax and grease remover.
(2) Verify that clutch housing alignment dowels
are in good condition and properly seated.
(3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Install structural dust cover if removed (Refer
to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL
COVER - INSTALLATION).
(5) Align and install clutch housing on engine (Fig.
14). Tighten housing bolts across the top of the hous-
ing first and to the following torque values:
²ªAº bolts 1/4in. diameter - 4.5 N´m (40 in.lb.)
²ªAº bolts 3/8in. diameter - 40 N´m (30 ft.lb.)
²ªAº bolts 7/16in. diameter - 68 N´m (50 ft.lb.)
²ªBº bolts for 5.7L 5.9L TD/8.0L engines - 47.5
N´m (40 ft.lb.)
²ªCº bolts for 5.7L engine - 68 N´m (50 ft.lb.)
²ªCº bolts for 5.9L TD engine - 47.5 N´m (35
ft.lb.)
²ªCº bolts for 8.0L engine - 74.5 N´m (55 ft.lb.)
(6) Install starter to clutch housing.
(7) Install transmission and transfer case, if
equipped.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped.
(2) Remove spring clip.
Fig. 11 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING FACE CIRCLE (AT RIM OF BORE)
Fig. 12 ALIGNMENT SHIMS
1 - CUT/DRILL BOLT HOLE TO SIZE
2 - SHIM STOCK
3 - MAKE SHIM 1-INCH DIAMETER
Fig. 13 TRANSMISSION/CLUTCH HOUSING-NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
DRCLUTCH 6 - 9
CLUTCH HOUSING (Continued)