Clutch Disc: Service and Repair
CLUTCH DISCREMOVAL
1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts.
2. Remove transmission and transfer case, if equipped.
3. If pressure plate will be reused, mark the position on flywheel with paint or scriber (Fig. 3). Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it.
4. Insert clutch alignment tool through clutch disc and into pilot bushing, to hold disc in place while removing bolts.
5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate.
6. Remove bolts completely and remove pressure plate, disc and alignment tool.
INSTALLATION
1. Check runout and free operation of new clutch disc.
2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease.
3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel.
NOTE: Flywheel side is imprinted on the disc face.
4. Install alignment tool in pilot bearing and position disc on the flywheel.
5. Position pressure plate over disc and onto the flywheel (Fig. 4).
6. Align and hold pressure plate in position and install bolts finger tight.
7. Tighten bolts evenly and a few threads at a time in a diagonal pattern.
CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover.
8. Tighten pressure plate bolts to:
^ V6 & V8 Engines 50 Nm (37 ft. lbs.)
^ V10 & Diesel Engines 30 Nm (22.5 ft. lbs.)
9. Remove release lever and release bearing from clutch housing. Apply Mopar high temperature bearing grease to bore of release bearing, release lever contact surfaces and release lever pivot stud (Fig. 5).
10. Apply light coat of Mopar high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of the transmission front bearing retainer (Fig. 6).
CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc.
11. Wipe pilot bearing surface clean.
12. Install release lever and bearing in clutch housing. Verify spring clips that retain fork on pivot ball and release bearing on fork are installed properly (Fig. 7).
NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission.
13. Install transmission and transfer case if equipped.
14. Check fluid level in clutch master cylinder.