Repair Procedure

This procedure involves installation of offset dowels and/or metal spacers to adjust the clutch housing alignment.


Clutch Housing Pilot Bore Runout Adjustment


1. Remove clutch housing and the two (2) original engine dowels.

2. Based on the TIR value select the appropriate pair of offset dowels from the chart below.

TIR 2.2L/2.5L 3.9L/5.2L/5.9L Dowel Offset
VALUE DOWEL PIN DOWEL PIN

.011" to .021" 4536315 1736347 .007"
.022" to .035" 4536316 1736348 .014"
.036" to .052" 4536317 1736353 .021"


NOTE: WHEN THE TIR VALUE IS GREATER THAN .052" THE CLUTCH HOUSING MUST BE REPLACED AND THE RUNOUT CHECKED ON THE NEW CLUTCH HOUSING.


3. Using a soft faced hammer install both offset dowels with the offset position in the direction that will counter the pilot bore offset.


NOTE: THE SLOTTED SIDE OF THE DOWELS MUST POINT AWAY FROM THE ENGINE.


4. Install the clutch housing, starting at the bolts closest to the dowels tighten the bolts to the following torques.

3/8" diameter bolt 30 ft.lbs (41 N-m)
7/16" diameter bolt 50 ft.bs (68 N-m)
12 mm diameter bolt 70 ft.lbs (95 N-m)

5. Remeasure clutch housing pilot bore runout. If runout is .010" or less proceed to Step 1 - Clutch Housing Face Squareness Adjustment. If runout exceeds .010" loosen clutch housing bolts, using a large screwdriver rotate dowels in the direction that will counter the pilot bore offset, torque the bolts and remeasure clutch housing pilot bore runout.

Figure 6:

Clutch Housing Face Squareness Adjustment

1. Based on the face squareness TIR value fabricate spacers out of appropriate thickness shim stock as shown in Figure 6. Mark each spacer location so that the spacer can be correctly positioned between the transmission and clutch housing during final assembly.

Figure 7:

2. Remove dial indicator, clutch housing and threaded rod. Install and tighten the flywheel bolt to one of the following torques.

2.2L/2.5L Engine 70 ft.lbs. (95 N-m)
3.9L/5.2L/5.9L Engine 55 ft.lbs. (75 N-m)

3. Thoroughly clean the input shaft clutch splines and clutch disc splines. They must be free of any dirt or rust. Apply a light coat of wheel bearing grease P/N 4318064 evenly to the entire length of the input shaft splines. Be sure all excessive grease is removed.

4. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing. Apply a light coat of multi-purpose grease P/N 4318063 to the inside of the pilot bushing.

5. Install clutch disc and cover, release fork and release bearing.

6. Install clutch housing. Starting at the bolts closest to the dowels tighten the bolts to the following torques.

3/8" diameter bolt 30 ft.lbs (41 N-m)
7/16" diameter bolt 50 ft.lbs (68 N-m)
12 mm diameter bolt 70 ft.lbs (95 N-m)

Install the clutch housing to engine struts (if any). Tighten the strut to clutch housing bolts first and then the strut to engine bolts to the above torque values.

7. Install the transmission. Be sure to locate the fabricated spacers in the correct positions (Figure 7).
POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 06-10-01-90 . . . . . . . . . . . . . 3.5 Hrs.

NOTE: THIS OPERATION DOES NOT INCLUDE TRANSMISSION REMOVE AND INSTALL.


FAILURE CODE: 64 - Misaligned or Mismatched