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CLUTCH
CONTENTS
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CLUTCH COMPONENTS
The clutch mechanism in AN models consists of a single, dry-type clutch disc and a diaphragm style clutch cover. A sleeve-type release bearing is used to engage and disengage the clutch cover pressure plate. The bearing is prelubricated during manufacture and is a sealed unit. The release bearing is operated by a pivoting release fork in the clutch housing. The fork pivots on a ball stud within the housing. The release fork is actuated by a hydraulic slave cylinder. The slave cylinder is operated by a clutch master cylinder connected to the clutch pedal. The clutch disc has cushion springs in the disc hub. The clutch disc facing is riveted to the hub. The facing is made from a non-asbestos material. The clutch cover pressure plate is a diaphragm type unit with a one-piece diaphragm spring and multiple release fingers. The pressure plate release fingers are preset during manufacture and are not adjustable. The transmission input shaft is supported in the crankshaft by a pilot bearing.
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CLUTCH
Do not apply grease to any part of the clutch cover or disc. Use Mopar multi mileage grease or a silicone grease for the clutch pedal bushings and pivot shaft. Use Mopar high temperature bearing grease or equivalent for the pilot bearing, release bearing bore, transmission input shaft and release fork components. Apply recommended amounts only and do not overlubricate. Refer to the Clutch Service section for specific information.
CLUTCH LUBRICATION
Proper clutch component lubrication is important to satisfactory operation. Using the correct lubricant and avoiding over lubrication are also equally important. During service, apply recommended lubricant sparingly. Do not overlubricate as this could result in clutch disc and pressure plate contamination. Clutch and transmission components requiring lubrication are: pilot bearing release lever pivot ball stud release lever pivot surfaces release bearing bore clutch pedal pivot bore and bushings. transmission input shaft splines and pilot hub release bearing slide surface of front bearing retainer
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GENERAL INFORMATION
Problem diagnosis will generally require a road test to determine the type of fault. Component inspection will then determine the problem cause after road testing. Drive the vehicle at normal speeds during the road test. Shift the transmission through all gear ranges and observe clutch action. If chatter, grab, slip, or improper release is experienced, remove and inspect the clutch components. However, if the problem is noise or hard shifting, further diagnosis may be needed. The transmission or another driveline component may actually be at fault. Careful observation during the test will help narrow the problem area.
Grease contamination is usually a product of excessive lubrication during clutch service. Apply only a small amount of grease to the input shaft splines, bearing retainer, pilot bearing, release fork and pivot stud. Excess grease can be thrown off during operation and contaminate the disc.
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.
FLYWHEEL MISALIGNMENT
Common causes of misalignment are heat warping, mounting the flywheel on a dirty crankshaft flange, incorrect bolt tightening, improper seating on the crankshaft flange shoulder, or loose crankshaft or flywheel bolts.
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CLUTCH
loose housing bolts, missing alignment dowels, or housing damage. Only rarely is misalignment caused by housing mounting surfaces that are not parallel. If housing misalignment is suspected, the housing is probably not fully seated on either the engine, alignment dowels, or transmission front face. Since the AX 15 and NV3500 clutch housings are either attached, or an integral part of the transmission gear case, it will be necessary to remove the transmission and housing as an assembly to check seating. Be sure the housing mounting surface is clean. Also be sure the housing alignment dowels are securely in place in the engine block and are in good condition. Replace the dowels if distorted, damaged, or doubt exists about dowel condition.
Very light scoring on the flywheel face can be cleaned up by scuff sanding with 120/180 grit emery cloth or sandpaper. However, the flywheel should be replaced if warped, or severely scored. Do not machine the flywheel. The flywheel face is manufactured with a unique surface contour. Machining would negate this feature resulting in unsatisfactory operation. 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. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout.
CLUTCH INSTALLATION METHODS AND PARTS USAGE Distortion of clutch components during installation or using non-standard components are additional causes of clutch malfunction. Improper clutch cover bolt tightening can distort the cover. The usual result is clutch grab, chatter and rapid wear. Tighten the cover bolts as described in Clutch Service section. Improperly seated flywheels and clutch housings are other causes of clutch failure. Improper seating will produce misalignment and clutch problems. Tighten all the clutch housing bolts to proper torque before installing any struts. Also be sure alignment dowels are in place and seated in the block and housing before bolt tightening. The use of non-standard or low quality parts can also lead to problems and wear. Use the recommended factory quality parts to avoid comebacks.
CLUTCH
CLUTCH INSPECTION CHART
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CLUTCH
CLUTCH SLIPS
CLUTCH
IMPROPER CLUTCH RELEASE
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CLUTCH
CLUTCH GRAB/CHATTER
CLUTCH
CLUTCH NOISE
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Cover and Disc Installation . . Cover and Disc Removal . . . Housing Replacement (AX 15) Hydraulic Linkage Installation Hydraulic Linkage Removal . .
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CLUTCH
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CLUTCH
(3) Remove pilot bearing. Use blind hole puller tools such as those included in Snap-On set CG40CB to remove bearing. (4) Clean bearing bore with solvent and wipe dry with shop towel. (5) Lubricate new pilot bearing with Mopar high temperature grease. (6) Position and start new bearing in bearing bore by hand. Note that pilot bearing has seal at one end. Install bearing so seal is facing outward toward transmission. (7) Seat pilot bearing with clutch alignment tool (Fig. 7). Keep bearing straight during installation. Do not allow bearing to become cocked. Tap bearing into place until flush with edge of bearing bore. Do not recess bearing. (8) Install transmission assembly.
essary followed by a wax and grease remover, or similar solvent. Also clean engine block surface as well. (5) Position replacement clutch housing on transmission and install housing attaching bolts. Tighten bolts to 38 Nm (28 ft. lbs.) torque. (6) Transfer release fork pivot ball stud to replacement housing if necessary. (7) Lubricate release bearing bore, release fork contact surfaces and release fork pivot stud with Mopar high temperature bearing grease. Also lubricate transmission input shaft splines, pilot hub and bearing retainer slide surface with light coat of same grease. (8) Install release fork and bearing in housing. Be sure release fork boot is properly seated in housing. (9) Install transmission as described in Group 21.
CLUTCH
(7) Remove retaining ring, flat washer and wave washer that attach clutch master cylinder push rod to clutch pedal (Fig. 8). (8) Slide clutch master cylinder push rod off clutch pedal pin. (9) Inspect condition of bushing on clutch pedal pin. Remove and replace bushing if worn or damaged. (10) Verify that cap on clutch master cylinder reservoir is tight. This is necessary to avoid undue spillage during removal. (11) Remove screws attaching clutch fluid reservoir to dash panel. (12) Pull clutch master cylinder rubber seal from dash panel (Fig. 8). (13) Rotate clutch master cylinder 45 counterclockwise to unlock it. Then remove cylinder from dash panel. (14) Remove hydraulic linkage components from vehicle.
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(3) Inspect bushing on the clutch pedal pin. Replace bushing if worn or damaged. (4) Remove snap ring and washer attaching clutch pedal to the pivot shaft. (5) Slide pedal off pivot shaft and remove pedal. (6) Remove and inspect bushings in pedal bore. Replace bushings if worn or cracked.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc and cover are removed for service. Check condition of the flywheel face, hub, starter ring gear teeth, and flywheel bolts. Minor scratches, burrs, or glazing on the flywheel face can be reduced with 120/180 grit emery cloth. However, the flywheel should be replaced if the disc contact surface is severely scored, heat checked, cracked, or obviously worn. Cleanup of minor flywheel scoring should be performed with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal is not recommended. The flywheel surface is manufactured with a unique contour which can be damaged by machining. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.). Excessive stock removal can also result in flywheel cracking or warpage after installation. It can also weaken the flywheel and interfere with proper clutch release. Check flywheel runout if misalignment is suspected. Runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the dial indicator on a stud installed in place of one of the flywheel attaching bolts. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing runout. Check condition of the flywheel hub and attaching bolts. Replace the flywheel if the hub exhibits cracks in the area of the attaching bolt holes. Install new attaching bolts whenever the flywheel is replaced. Apply Mopar Lock-N-Seal, or Loctite 242 on the replacement bolt threads before installation.
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CLUTCH
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