DODGE RAM 2002 Service Repair Manual

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
OPERATION............................2
WARNING.............................2
DIAGNOSIS AND TESTING - CLUTCH........2
SPECIFICATIONS - CLUTCH...............7
CLUTCH DISC
REMOVAL.............................7
INSTALLATION..........................8
CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH
HOUSING............................9
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH RELEASE BEARING
REMOVAL.............................12
INSTALLATION.........................12FLYWHEEL
DIAGNOSIS AND TESTING - FLYWHEEL.....13
DISASSEMBLY.........................13
ASSEMBLY............................14
PILOT BEARING
REMOVAL.............................14
INSTALLATION.........................14
CLUTCH PEDAL
REMOVAL.............................15
INSTALLATION.........................15
LINKAGE
REMOVAL.............................15
INSTALLATION.........................16
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................17
OPERATION...........................17
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, dry-
type disc, diaphragm style pressure plate (Fig. 1) and
hydraulic linkage. The flywheel is bolted to the rear
flange of the crankshaft. The clutch pressure plate is
bolted to the flywheel with the clutch disc between
these two components. The clutch system provides
the mechanical, link between the engine and the
transmission. The system is designed to transfer the
torque output of the engine, to the transmission
while isolating the transmission from the engine fir-
ing pulses to minimize concerns such as gear rattle.
Fig. 1 ENGINE POWERFLOW
BR/BECLUTCH 6 - 1

OPERATION
When the clutch pedal is depressed, it actuates the
clutch master cylinder. This sends hydraulic pressure
to the clutch slave cylinder. The release fork is then
actuated by the slave cylinder mounted on the trans-
mission housing. The release fork pivots on a ball
stud mounted in the transmission housing and
pushes the release bearing. The release bearing then
depresses the pressure plate spring fingers, thereby
releasing pressure on the clutch disc and allowing
the engine crankshaft to spin independently of the
transmission input shaft (Fig. 2).
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 AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS 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 COMPONENTSWITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE 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 CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING - CLUTCH
A road test and component inspection (Fig. 3) is
recommended to determine a clutch problem.
During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
ranges and observe clutch action. If the clutch chat-
ters, grabs, slips or does not release properly, remove
and inspect the clutch components. If the problem is
noise or hard shifting, further diagnosis may be
needed as the transmission or another driveline com-
ponent may be at fault.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, water or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter,
slip and grab.
During inspection, note if any components are con-
taminated with oil, hydraulic fluid or water/road
splash.
Oil contamination indicates a leak at either the
rear main seal or transmission input shaft. Oil leak-
age produces a residue of oil on the housing interior
and on the clutch cover and flywheel. Heat buildup
caused by slippage between the cover, disc and fly-
wheel, can sometimes bake the oil residue onto the
components. The glaze-like residue ranges in color
from amber to black.
Road splash contamination means dirt/water is
entering the clutch housing due to loose bolts, hous-
ing cracks or through hydraulic line openings. Driv-
ing through deep water puddles can force water/road
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals.
Fig. 2 CLUTCH OPERATION
1 - FLYWHEEL
2 - PRESSURE PLATE FINGERS
3 - PIVOT POINT
4 - RELEASE BEARING PUSHED IN
5 - CLUTCH DISC ENGAGED
6 - CLUTCH DISC ENGAGED
7 - RELEASE BEARING
6 - 2 CLUTCHBR/BE
CLUTCH (Continued)

Fig. 3 CLUTCH COMPONENTS AND INSPECTION
BR/BECLUTCH 6 - 3
CLUTCH (Continued)

IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems are caused
by wear or damage to one or more clutch compo-
nents. A visual inspection of the release components
will usually reveal the problem part.
Release problems can result in hard shifting and
noise. Items to look for are: leaks at the clutch cylin-
ders and interconnecting line; loose slave cylinder
bolts; worn/loose release fork and pivot stud; dam-
aged release bearing; and a worn clutch disc, or pres-
sure plate.
Normal condensation in vehicles that are stored or
out of service for long periods of time can generate
enough corrosion to make the disc stick to the fly-
wheel, or pressure plate. If this condition is experi-
enced, correction only requires that the disc be
loosened manually through the inspection plate open-
ing.
Engagement problems usually result in slip, chat-
ter/shudder, and noisy operation. The primary causes
are clutch disc contamination; clutch disc wear; mis-
alignment, or distortion; flywheel damage; or a com-
bination of the foregoing. A visual inspection is
required to determine the part actually causing the
problem.
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.
DIAGNOSIS CHART
The clutch inspection chart (Fig. 3) outlines items
to be checked before and during clutch installation.
Use the chart as a check list to help avoid overlook-
ing potential problem sources during service opera-
tions.
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction.
Fault conditions are listed at the top of each chart.
Conditions, causes and corrective action are outlined
in the indicated columns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
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.
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.
6 - 4 CLUTCHBR/BE
CLUTCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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 and 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.
Pilot bearing seized, loose, or rollers
are worn.1. Bearing cocked during
installation.1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
BR/BECLUTCH 6 - 5
CLUTCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Add Fluid / Replace hydraulic
linkage assembly.
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.
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.
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.3. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andùr
clutch housing. Correct as
necessary.
6 - 6 CLUTCHBR/BE
CLUTCH (Continued)

SPECIFICATIONS - CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut, slave cylinder 19-26 14-19 170-230
Bolt, clutch cover-5/16 in. 23 17 -
Bolt, clutch cover-3/8 in. 41 30 -
Pivot, release bearing 23 17 -
Screw, fluid reservoir 5 - 40
CLUTCH DISC
REMOVAL
(1) Raise and support vehicle.
(2) Support engine with wood block and adjustable
jack stand, so engine mounts are not strained (Fig.
4).
(3) Remove transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case for procedures.(4) If pressure plate will be reused, mark position
of cover on flywheel with paint or scriber (Fig. 5).
(5) Insert clutch alignment tool through clutch disc
and into pilot bushing, to hold disc in place.
Fig. 4 Supporting Engine -Diesel Model Shown
1 - WOOD BLOCK
2 - ADJUSTABLE JACK STAND
Fig. 5 Marking Pressure Plate Position
1 - FLYWHEEL
2 - ALIGNMENT MARKS
3 - PRESSURE PLATE
BR/BECLUTCH 6 - 7
CLUTCH (Continued)

(6) If pressure plate will be reused, loosen cover
bolts evenly only few threads at a time in a diagonal
pattern (Fig. 6). This relieves cover spring tension
evenly to avoid warping.
(7) Remove bolts completely and remove plate, disc
and alignment tool.
INSTALLATION
(1) Check runout and free operation of new clutch
disc.
(2) Insert clutch alignment tool in pressure plate
and clutch disc.
(3) Insert alignment tool in pilot bearing and posi-
tion plate and disc on flywheel (Fig. 7).
NOTE: Raised side of disc hub faces away from the
flywheel.
(4) Iinstall cover bolts finger tight.
(5) Tighten cover bolts evenly and a few threads at
a time.
CAUTION: Cover bolts must be tightened evenly to
avoid distorting cover.
(6) Tighten clutch cover bolts to:
²5/16 in. diameter bolts to 23 N´m (17 ft. lbs.).
²3/8 in. diameter bolts to 41 N´m (30 ft. lbs.).(7) Remove release lever and release bearing from
clutch housing. Apply Mopar high temperature bear-
ing grease or equivalent to bore of release bearing,
release lever contact surfaces and release lever pivot
stud (Fig. 8).
(8) Apply light coat of Mopar high temperature
bearing grease or equivalent to splines of transmis-
sion input shaft (or drive gear) and to release bearing
slide surface of the transmission front bearing
retainer (Fig. 9).
CAUTION: Do not over lubricate shaft splines. This
can result in grease contamination of disc.
(9) Install release lever and bearing in clutch
housing. Be sure spring clips that retain fork on
pivot ball and release bearing on fork are secure (Fig.
10). Also verify that the release lever is installed
properly.
NOTE: Release lever is installed correctly, when
lever part number is toward the bottom of the trans-
mission. Also a stamped ªIº in the lever goes
towards the pivot ball side of the transmission.
(10) Install transmission. Refer to 21 Transmission
and Transfer Case for procedures.
(11) Check fluid level in clutch master cylinder.
Fig. 6 Bolt Loosening/Tightening Pattern
Fig. 7 Pressure Plate And Disc Alignment
1 - FLYWHEEL
2 - PRESSURE PLATE AND DISC
3 - CLUTCH DISC ALIGNMENT TOOL
6 - 8 CLUTCHBR/BE
CLUTCH DISC (Continued)

CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH HOUSING
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 and strut.
(2) Remove the clutch cover and disc.
Fig. 8 Clutch Release Component Lubrication
Points
1 - CLUTCH HOUSING
2 - RELEASE FORK PIVOT BALL STUD
3 - RELEASE FORK
4 - RELEASE BEARING BORE
5 - LUBE POINTS (HIGH TEMP. GREASE)
Fig. 9 Lubrication Points
1 - INPUT SHAFT
2 - BEARING RETAINER
3 - LUBRICATION POINTS
Fig. 10 Release Fork And Bearing Spring Clip
Position
1 - FORK
2 - SPRING CLIP
3 - BEARING
4 - SPRING CLIP
BR/BECLUTCH 6 - 9
CLUTCH DISC (Continued)