torque DODGE RAM 1999 Service Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 357 of 1691
ROTOR
CAUTION: DO NOT allow caliper to hang by brake hose.
Inspection
1) Raise and support vehicle. Remove wheels. On Dakota 4WD,
reinstall and tighten lug nuts to secure rotor. On Dakota 2WD, Ram
Pickup and Ram Van, remove dust cap, and temporarily adjust wheel
bearings to zero end play.
2) On all models, mount dial indicator on steering arm, with
plunger contacting rotor about 1" (25 mm) from edge of rotor. Slowly
rotate rotor, and note lateral runout. Lateral runout on either side
of rotor should not exceed specification. See DISC BRAKE
SPECIFICATIONS.
3) On Dakota, check runout of hub face if runout exceeds
specification. Before removing rotor, make a chalk mark across rotor
and one wheel stud. Make mark on high side of runout.
4) Remove rotor from hub. Install dial indicator on steering
arm, with stem contacting hub face near outer diameter. Place dial
indicator stem outside stud circle but inside chamfer on hub rim. If
runout exceeds specification See DISC BRAKE SPECIFICATIONS. Hub must
be replaced.
5) If hub runout is within specification, install rotor on
hub with chalk marks 180 degrees apart. Install wheel lug nuts, and
recheck rotor runout. If runout is not within specification, resurface
or replace rotor.
6) On all models, measure rotor parallelism. To measure
parallelism, measure rotor thickness with micrometer at 12 equal
points around rotor radius approximately 1" (25 mm) from edge of
rotor. If thickness varies more than parallelism specification,
resurface or replace rotor. See DISC BRAKE SPECIFICATIONS.
Removal (Dakota 2WD, Ram Pickup 2WD (5 Studs), & Ram Van)
Raise and support vehicle. Remove wheels. Remove brake
caliper from adapter. Support caliper aside. Remove grease cap, cotter
pin, nut lock, nut, thrust washer and outer wheel bearing. Pull rotor
assembly off spindle.
Installation
1) Slide rotor assembly into position on spindle. Pack and
install outer wheel bearing, thrust washer and nut. While rotating
rotor and hub assembly, tighten wheel bearing nut to specification.
See TORQUE SPECIFICATIONS table.
2) Back off nut to release preload. Retighten nut finger
tight. Install nut lock and cotter pin. Coat inside of cap with
grease, and install cap. To complete installation, reverse removal
procedure.
Removal (Ram Pickup With Tapered Bearings)
1) Raise and support vehicle. Remove wheel. Remove brake
caliper and adapter. Support caliper aside. Remove grease cap and
driving hub snap ring. Remove drive hub and spacer.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove grease
cap, cotter pin and bearing adjuster nut. Remove thrust washer and
outer wheel bearing. Remove rotor and hub assembly from spindle.
Installation
1) Apply liberal coat of wheel bearing grease to spindle.
Install hub and rotor on spindle. Pack and install outer bearing.
Install thrust washer and bearing adjuster nut. Tighten nut only
enough to remove end play at his time.
2) Install caliper. DO NOT seat caliper pistons and brake
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pads at this time. On models with removable hub, install hub on rotor.
Install wheel and tire assembly. Tighten lug nuts so they are snug,
but DO NOT tighten to final torque specifications.
3) While rotating wheel, tighten adjuster nut sufficiently to
seat bearing. Loosen nut and retighten while still rotating wheel.
Back off adjuster nut to completely release bearing preload torque.
Ensure endplay of .001-.003" (.025-.076 mm). Install lock nut and NEW
cotter pin. If necessary, tighten lock nut slightly to align cotter
pin hole. Install grease cap. Tighten caliper bolts and lug nuts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse remove procedure.
Removal (Ram Pickup With 8 Studs)
1) Raise and support vehicle. Remove wheel. Remove hub
extension, if equipped. Remove brake caliper. Support caliper aside.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove cotter
pin from rotor hub nut. Remove nut. Disconnect ABS wheel speed sensor
wire (if equipped), and remove from frame and steering knuckle. Remove\
bolts securing hub to steering knuckle from inboard side of steering
knuckle. Remove rotor and hub assembly.
Installation
1) Apply anti-seize compound to drive shaft splines. Replace
grease seal in steering knuckle, if necessary. Insert 2 rearmost top
and bottom rotor hub bolts in steering knuckle so they extend through
back of knuckle. Install hub spacer, ensuring flat on space is
positioned to rear. Use chassis grease to hold spacer in position, if
necessary.
NOTE: If equipped with wheel speed sensor, brake shield must be
positioned on hub bearing, and sensor wire must be at top of
knuckle.
2) Align rotor hub with drive shaft and install hub assembly.
Align bolt holes in hub flange with bolts previously installed. Start
nuts on flange bolts sufficiently to hold assembly in place. Install
remaining bolts, and tighten all bolts to specification. See TORQUE
SPECIFICATIONS table.
3) Install washer and hub nut. Tighten nut securely. Install
NEW cotter pin. Install grease cap. Install caliper. Tighten caliper
bolts and lug nuts to specification. See TORQUE SPECIFICATIONS table.
To complete installation, reverse remove procedure.
REAR BRAKE SHOES
WARNING: Use water or brake cleaner to clean brake parts. DO NOT use
compressed air to remove dirt and dust.
Removal (Dakota & Ram Van)
1) Remove wheel and drum. Note how secondary spring overlaps
primary return spring. Using spring remover, remove brake shoe return
springs. Slide automatic adjuster cable off anchor. Disconnect cable
from adjusting lever.
2) Remove cable, cable guide and anchor plate. See Figs. 3,
4, and 5. Disconnect adjusting lever return spring from lever. Remove
lever and return spring from pivot pin. Remove shoe-to-shoe spring.
Spread shoes, and remove adjustment star wheel.
3) Remove shoe retainers, springs and pins. Remove parking
brake lever from secondary shoe. Remove shoes and parking brake strut
with spring.
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Removal & Installation
1) Disconnect and plug primary and secondary brakelines from
master cylinder. Remove master cylinder-to-power brake booster nuts.
Slide master cylinder straight out and away from power brake booster
unit.
2) Ensure reservoir is empty. Install master cylinder in
soft-jaw vise. Pry gently upward between reservoir ports while working
reservoir side to side. Remove reservoir and grommets. See Fig. 6.
3) Install NEW grommets in master cylinder ports. Lubricate
grommets with brake fluid. Firmly and evenly, press reservoir into
grommets by hand.
4) To complete installation, position master cylinder over
studs of power brake booster. Align power cylinder brake push rod with
cylinder piston. Install master cylinder nuts, and tighten to
specification. See TORQUE SPECIFICATIONS table. Connect both
brakelines. Bleed system. See BLEEDING BRAKE SYSTEM.
Fig. 6: Exploded View Of Master Cylinder (Ram Pickup)
Courtesy of Chrysler Corp.
POWER BRAKE BOOSTER
Removal
1) Disconnect vacuum hose from booster check valve. Remove
nuts attaching master cylinder, and move cylinder away from booster.
Inside vehicle, remove booster push rod-to-brake pedal clip. Pry clip
off pedal pivot pin.
2) Remove lock nuts from booster mounting studs. Slide
booster away from dash and out of engine compartment. If booster is
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being replaced, remove booster check valve and seal.
Installation
1) If new booster is being installed, install check valve and
seal. Position booster on dash, and install lock nuts on booster
mounting studs finger tight. Install booster push rod on brake pedal
pin, and secure rod with NEW retaining clip.
2) Tighten booster lock nuts to specification. Install master
cylinder on booster, and tighten mounting nuts to specification. See
TORQUE SPECIFICATIONS table. Connect vacuum hose to booster check
valve. Start vehicle and check booster operation.
COMBINATION VALVE
Removal & Installation
Raise and support vehicle. Mark brakelines for assembly
reference. Disconnect parking brake cable from clip on valve, if
necessary. Disconnect brake warning light connection at switch.
Disconnect all brake hydraulic lines at valve. Cap brakelines to
prevent dirt from entering system. Remove valve. To install, reverse
removal procedures. Bleed brake system. See BLEEDING PROCEDURES under
BLEEDING BRAKE SYSTEM.
AXLE BEARING & SEAL (FULL FLOATING AXLE)
Removal & Installation (Ram Pickup With 12" & 13" Drums)
1) Raise and support vehicle. Remove wheel. Remove axle shaft
nuts and washers. Strike center of axle flange to free cones. Remove
axle shaft and gasket.
2) Straighten and remove nut lock. Remove adjustment nut and
outer bearing. Remove drum assembly. Remove seal and inner bearing
from drum assembly.
3) Pack inner bearing, and install inner bearing and seal in
drum. Install drum assembly, outer bearing and adjustment nut. While
rotating drum, tighten adjustment nut to specification. See TORQUE
SPECIFICATIONS table.
4) Back off adjustment nut 1/8 turn to obtain .001-.010" (0.
025-0.254 mm) end play. Bend nut lock into spindle keyway. Install
gasket and axle shaft. Install wheel, and lower vehicle. See TORQUE
SPECIFICATIONS table.
OVERHAUL
NOTE: Use illustrations when overhauling components. See
Figs. 2-6.
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS \
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Application In. (mm)\
Disc Diameter
Dakota ............................................... 11.30 (287)\
Ram Pickup
1/2 Ton ............................................. 11.57 (294)\
3/4 & 1 Ton ......................................... 12.50 (318)\
Ram Van
1/2 & 3/4 Ton ....................................... 11.75 (299)\
1 Ton ............................................... 12.82 (326)\
Lateral Runout
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![DODGE RAM 1999 Service Owners Manual TORQUE SPECIFICATIONS
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Axle Adjustment Nut .............................. 120-140 (163-190)\
Axle Shaft Flange Or Support Plate Mounting Nuts
Dakota .................................................. 47 (64)\
Ram Pickup ........................................ 35-50 (48-68)\
Ram Van ................................................ 85 (115)\
Bearing/Hub Assembly Mounting Bolts ...................... 125 (170)\
Brake Booster Mounting Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Brake Hose Front Bolt (Dakota) ............................. 21 (29\
)
Brake Hose Front Fitting (Dakota) .......................... 12 (16\
)
Brake Hose Rear Fitting (Dakota) ........................... 14 (19\
)
Brakeline Fittings Combination Valve
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Master Cylinder
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Wheel Cylinder
Dakota ................................................... 12 (16)\
Ram Pickup ............................................... 10 (14)\
Brake Pedal Shaft Nut (Ram Van) ............................ 40 (54\
)
Caliper Adapter Bolts (Ram Van)
1/2 Ton ................................................ 130 (176)\
3/4 & 1 Ton ............................................ 210 (285)\
Caliper Mounting Bolts
Dakota (Guide Pins) ...................................... 22 (30\
)
Ram Pickup ............................................... 38 (52)\
Ram Van .................................................. 24 (33)\
Combination Valve Mounting Bolt (Ram Pickup) ............... 17 (23\
)
Diesel Hydraulic Booster Hoses (Ram Pickup) ................ 23 (31\
)
Diesel Hydraulic Booster Lines (Ram Pickup) ................ 21 (29\
)
Diesel Hydraulic Booster Mounting Bolts (Ram Pickup) ....... 21 (29\
)
Drive Flange Lock Nuts (4WD) ............................... 65 (88\
)
Master Cylinder Nuts
Dakota
1998 .................................................... 21 (29)\
1999 .................................................... 13 (18)\
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 17 (23)\
Park Brake Pedal Assembly Mounting Bolts/Nuts
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 40 (54)\
Pivot Pin .................................................. 30 (41)\
Power Booster Lock Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Proportioning Valve Brake Hose (Ram Pickup) ................ 23 (31\
)
Proportioning Valve Brakelines (Ram Pickup) .......... 14-17 (19-23\
)
Proportioning Valve Mounting Nuts (Ram Pickup) ............. 25 (34\
)
Wheel Bearing Outer Lock Nut (4WD) ......................... 65 (88\
)
Wheel Cylinder Mounting Bolts
1/4" Bolts (Dakota) ...................................... 11 (15\
)
5/16" Bolts (Dakota) ..................................... 16 (22\
)
Ram Pickup & Ram Van ..................................... 15 (20)\
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REMOVAL & INSTALLATION
TRANSFER CASE
CAUTION: When removing transfer case, DO NOT allow drive shafts to
hang free, as damage to "U" joints may result.
Removal (NV231HD, NV241HD & NV241LD - Ram Pickup)
1) Raise and support vehicle. Remove skid plate (if
equipped). Drain lubricant from transfer case if transfer case is
being repaired. Mark drive shafts and "U" joints for reassembly
reference. Disconnect speed sensor wires. Disconnect vent harness and
vent hose from transfer case switch.
2) Disconnect shift rod from grommet in transfer case shift
lever, or from floor arm, whichever provides easy access. Using slip
joint pliers, press rod out of lever grommet. See Fig. 8. Support
transmission with jackstand. Remove rear crossmember. Remove front and
rear drive shafts. Remove transfer case-to-transmission housing nuts.
Using transmission jack, support transfer case. Move transfer case
rearward until free of transmission. Remove transfer case from under
vehicle.
Removal (NV231 & NV242 - Dakota)
1) Shift transfer case into neutral. Raise vehicle. If
transfer case will be repaired, drain lubricant. Mark driveshafts and
"U" joints for reassembly reference. Support transmission with
jackstand. Remove rear crossmember and skid plate, if equipped.
2) Disconnect front and rear driveshafts at transfer case.
Disconnect transfer case linkage rod from shift lever. Disconnect
transfer case vent hose and electrical connectors. Support transfer
case with transmission jack. Remove nuts attaching transfer case to
transmission. Remove transfer case.
Installation (All Models)
To install, reverse removal procedure. If necessary fill
transfer case with MOPAR ATF Plus or Dexron-II. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table. Adjust shift
linkage, if necessary. See SHIFT LINKAGE ADJUSTMENT under ADJUSTMENTS.
Fig. 8: Removing Transfer Case Shift Mechanism (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
TRANSMISSION (DAKOTA)
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Removal (AX15 & NV1500)
1) Shift gear selector into 1st or 3rd gear. Raise and
support vehicle. Disconnect necessary exhaust system components.
Remove "Y" pipe and position remaining pipes for working clearance.
Support transmission adjustable jackstand. Disconnect rear cushion and
mounting bracket from transmission or transfer case.
2) Remove rear crossmember. If transmission will be
disassembled for repair, drain transmission fluid. Disconnect
transmission shift linkage, speedometer cable, transfer case vacuum
lines and clutch hydraulic lines. Lower transmission/transfer case
assembly no more than 3" (76 mm). Reaching around transmission case,
unseat and lift shift lever dust boot. Press shift lever retainer
downward, turn retainer counterclockwise, and lift lever and retainer
out of shift tower.
3) Mark front and rear drive shaft and "U" joint for
reassembly reference. Disconnect and remove both drive shafts. Remove
crankshaft position sensor (AX15). Disconnect transmission/transfer
case assembly vent hoses. Remove slave cylinder from clutch housing.
Remove wire harness from clips on transmission case and transfer case.
4) Support transmission/transfer case assembly with
transmission jack. Secure assembly to jack with safety chains.
Reposition adjustable jackstand under engine. Remove clutch housing
brace rod. Remove clutch housing nuts and bolts. Remove
transmission/transfer case assembly.
Installation
To install, reverse removal procedure. Apply high-temperature
grease to release fork, lever, pivot ball stud and pilot bushing
located in end of crankshaft. Fill transmission with appropriate
fluid, if necessary. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS table.
Removal (NV 3500)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Open console lid and remove bolts attaching console to floor
pan. Lift cup holder bin and remove bolt attaching console to floor
pan. Lift rear of console and pull console rearward to separate from
shift bezel. Remove console from vehicle. Remove screws attaching
shift boot to floor pan and slide boot upward on lever extension.
2) Remove shift lever extension. Raise and support vehicle.
On 4WD models, remove skid plate, if equipped. Mark drive shaft and
axle yoke for alignment reference. Remove drive shaft. Remove exhaust
"Y" pipe. On 4WD models, disconnect and lower remaining exhaust pipes
for clearance as necessary. Disconnect speed sensor harness connector
and back-up light harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine attaching bolts. Slide
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transmission and jack rearward until input shaft clears clutch disc.
Lower transmission jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke. Apply sealer to threads of drain plug
before installing in case.
2) Align reference marks made on drive shaft(s) and "U"
joints during removal. After installing clutch assembly and housing,
tighten housing bolts nearest alignment dowels first. During final
transmission installation, install shims between clutch housing and
transmission at appropriate bolt location. Tighten all nuts and bolts
to specification. See TORQUE SPECIFICATIONS table.
TRANSMISSION (RAM PICKUP)
Removal (NV3500 & NV5600)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Remove shift tower and lever assembly. Raise and support
vehicle.
2) On 4WD models, remove skid plate, if equipped. Remove
crankshaft position sensor. Mark drive shaft and axle yoke for
alignment reference. Remove drive shaft. Remove exhaust "Y" pipe. On
4WD models, disconnect and lower remaining exhaust pipes for
clearance, as necessary. Disconnect speed sensor harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover. On
some models, it may be necessary to remove front axle struts and oil
filter for access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
Removal (NV4500 & NV4500HD)
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1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Scribe mark position of extension on shank of shift lever.
2) Raise and support vehicle. On 4WD models, remove skid
plate, if equipped. Mark drive shaft and axle yoke for alignment
reference. Remove drive shaft. Remove exhaust "Y" pipe. On 4WD models,
disconnect and lower remaining exhaust pipes for clearance as
necessary. Disconnect speed sensor harness connector and back-up light
harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
See Fig. 9 . On 4WD models, disconnect transfer case shift linkage at
transfer case range lever and remove shift lever from transmission.
Remove bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and move it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder, and move aside. Remove
starter. Remove transmission splash shield. Remove transmission
harness wires from clips on transmission shift cover. On some models,
it may be necessary to remove front axle struts and oil filter for
access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and propeller shift slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first.
3) During final transmission installation, install shims
between clutch housing and transmission at appropriate bolt location.
See CLUTCH HOUSING BORE RUNOUT and CLUTCH HOUSING FACE RUNOUT under
CLUTCH HOUSING (RAM PICKUP) under TESTING. Press extension to scribe
mark made during removal. A 0.12-0.20" (3-5 mm) space should exist
between shift lever isolator, top edge of stub shaft and tool lower
jaw. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS table.
Fig. 9: Identifying Transmission Drain Bolt (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
CLUTCH ASSEMBLY
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CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components,
use a water-dampened cloth.
Removal
With transmission and clutch housing removed, mark pressure
plate and flywheel for reassembly reference. Install clutch aligner in
clutch disc to prevent disc from falling. Loosen pressure plate bolts
evenly and in rotation to avoid warping pressure plate. Remove
pressure plate and disc from flywheel. See Fig. 10.
Inspection
1) Check for oil leakage through engine rear main bearing oil
seal and transaxle input shaft seal. Check flywheel and pressure plate
for burned areas, discoloration, cracks, grooves or ridges. Replace as
necessary.
2) Use medium sandpaper (80-180 grade) to clean flywheel
surface, then wipe with mineral spirits. DO NOT flat-machine flywheel
surface. Check facing surfaces for grease or oil contamination. Check
clutch disc for wear. Clutch disc face-to-rivet head distance should
be at least .008" (.20 mm). Check splines of disc hub and transaxle
input shaft.
3) Using straightedge, check pressure plate. Friction area
should be flat to slightly concave, with the inner diameter about 0-.
0039" (0-0.1 mm) less than outer diameter. Using surface plate, check
clutch cover for flatness. Sections around bolt holes should contact
surface plate within .015" (.38 mm). Ensure cover-to-flywheel dowel
fit is snug. Replace clutch assembly as necessary.
NOTE: Before installing clutch disc, ensure flywheel mating
surface, pilot bearing/bushing and clutch release bearing are
in satisfactory condition. Repair and/or replace components
as necessary.
Installation
To install, reverse removal procedure using clutch aligner.
Ensure reference marks are aligned. Tighten pressure plate retaining
bolts evenly a few threads at a time to prevent warpage. See TORQUE
SPECIFICATIONS table.
Fig. 10: Exploded View Of Clutch Assembly (Typical)
Courtesy of Chrysler Corp.
PILOT BEARING, CLUTCH RELEASE BEARING & FORK