M/T - Clutch Housing and Structural Cover Installation
NUMBER: 21-004-02GROUP: Transmission
DATE: Dec. 13, 2002
SUBJECT:
3.7L, 4.7L, and 5.7L Clutch Housing and Structural Cover Installation
MODELS:
2000 - 2003 (AN) Dakota
2002 - 2003 (DR) Ram Pickup
NOTE:
THIS BULLETIN APPLIES TO 2000 - 2003 (AN) DAKOTA TRUCKS EQUIPPED WITH A 4.7L ENGINE (SALES CODE EVA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36). 2002 - 2003 (DR) RAM TRUCK EQUIPPED WITH 3.7L, 4.7L OR 5.7L ENGINE (SALES CODE EKG, EVA, OR EZA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36, A64, OR A74).
DISCUSSION:
The clutch housing maintains alignment between the crankshaft and transmission input shaft. The structural cover provides additional powertrain stiffness and reduces noise and vibration. If either one is bolted to the engine or to each other, in the wrong sequence, drivetrain misalignment could result. Misalignment could result in reduced life expectancy of drivetrain components such as the clutch disc assembly, pilot bearing, clutch release components, and transmission.
If misalignment is suspected and the clutch housing bore runout is found to be excessive using the diagnostic procedures in the service manual or if the clutch housing and structural cover has been removed for any reason, the components should be installed using the following Repair Procedure.
REPAIR PROCEDURE:
1. Open the hood.
2. Disconnect the negative battery cable.
3. Remove the transmission as outlined in the service information available in MDS2 or the 2003 DR Ram Truck Service Manual (Publication No. 81-370-03059) page 21-43 (5.7L only).
4. Clean the clutch housing mounting surface of the engine block using Mopar Engine Degreaser pin 04318040 (or equivalent).
5. Verify that the clutch housing alignment dowels are in good condition and properly seated.
CAUTION:
THE STRUCTURAL COVER MUST BE INSTALLED AS DESCRIBED IN THE FOLLOWING STEPS. FAILURE TO DO SO WILL CAUSE SEVERE DAMAGE TO THE COVER, AND ENGINE NOISE.
6. Align and install the clutch housing and the structural cover on the back of the block in the following sequence:
a. Install four (4) clutch housing to engine (3/8 in. diameter) bolts located at the top of the clutch housing and torque to 40.6 Nm (30 lb ft).
b.Install dust shield (1/4 in. diameter) bolt and torque to 4.5 Nm (40 in. lbs.).
c. Position structural cover flush to the engine block and the clutch housing, and hold in position while hand starting the fasteners.
CAUTION:
THE STRUCTURAL COVER MUST BE HELD TIGHTLY AGAINST THE CORNER FORMED BY THE ENGINE AND THE TRANSMISSION CLUTCH HOUSING DURING TIGHTENING SEQUENCE. FAILURE TO DO SO MAY CAUSE DAMAGE TO THE COVER AND ENGINE NOISE.
d. Tighten two (2) structural cover fasteners (Item 3 & 7) (Fig. 1) to the clutch housing and torque to 5 - 11 Nm (50-100 in. lbs).
e. Install four (4) structural cover fasteners (Items 2, 4, 5, & 6) (Fig. 1) to the engine and torque to 5 - 11 Nm (50-100 in. lbs).
7. Torque the six (6) structural cover bolts installed in steps d & e above in the following order:
a. Torque the bolt that is closest to the rear face of block on the passenger side (Item 4) (Fig. 1) to 54 Nm (40 ft. lbs.).
b. Torque the bolt that is closest to the front face of the block on the driver side (Item 5) (Fig. 1) to 54 Nm (40 ft. lbs.).
c. Torque the bolt that is closest to the front face of the block on the passenger side (Item 2) (Fig. 1) to 54 Nm (40 ft. lbs.).
d. Torque the bolt that is closest to the rear face of the block on the driver side (Item 6) (Fig. 1) to 54 Nm (40 ft. lbs.).
e. Torque two (2) structural cover bolts to the clutch housing (Item 3 & 7) to 54 Nm (40 ft. lbs.).
8. Install the (2 - 5.7L) (4 - 3.7L & 4.7L) engine to housing bolts (7/16 in. diameter bolts) and torque to 68 Nm (50 ft. lbs.), as a last step.
9. Install transmission (5.7L only) and transfer case if equipped.
NOTE:
IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK WHEN THE PROCEDURE IS COMPLETE.
10. Reconnect the negative battery cable.
POLICY:
Information Only.