1993 DODGE TRUCK Service Repair Manual

e - 4
CLUTCH

•
7/16 - 20
THREAD
NUT
10 INCHES LONG J9006-25

CLUTCH
HOUSING

BORE
J9006-26

Fig.
2 Checking Clutch Housing Bore Runout
.000
CLUTCH
HOUSING

qroe {Smm READINGS) J9006-27

Fig.
3
Housing
Bore Measurement Points And Sample Readings
MEASURING
CLUTCH
HOUSING FACE
RUNOUT (GAS AND DIESEL ENGINES) (1) Reposition the dial indicator plunger on the
housing face (Fig. 5). Place the indicator plunger at
the rim of the housing bore as shown.
(2) Rotate the crankshaft until the indicator
plunger is at the 10 O'clock position on the bore.
Then zero the dial indicator.
SLOT SHOWS DIRECTION OFFSET
DOWEL
DOWEL SELECTION
TIR
VALUE OFFSET DOWEL

REQUIRED
0.011
-0.021
inch
0.007
inch

0.022
-
0.035
inch
0.014
inch

0.036
-
0.052
inch
0.021
inch

J9206-7
Fig.
4
Housing
Bore
Alignment
Dowel
Selection

(3)
Measure and record face runout at four points
90° apart around the housing face (Fig. 6). Perform
the measurement at least twice for accuracy.

(4)
Subtract the lowest reading from the highest to
determine total runout. As an example, refer to the
sample readings shown in Figure 6. If the low read­
ing was minus
0.004
in. and the highest reading was
plus
0.009
in., total runout is actually
0.013
inch.

(5)
Total allowable face runout is 0.010 inch. If
runout exceeds this figure, runout will have to be
corrected. Refer to Correcting Clutch Housing Face
Runout.

CORRECTING CLUTCH HOUSING FACE
RUNOUT

Housing face runout, on gas or diesel engines, can
be corrected by installing shims between the clutch
housing and transmission (Fig. 7). The shims can be made from shim stock or similar materials of the re­
quired thickness.
As an example, assume that face runout is the
same as shown in Figure 6 and in step (4) above. In
this case, three shims will be needed. Shim thick­
nesses should be
0.009
in. (at the
0.000
corner),
0.012
in. (at the
-0.003
corner) and
0.013
in. (at the
-0.004

corner).
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow­ els first.
Clutch housing preferred bolt torques are:
• 41 N-m (30 ft. lbs.) for 3/8 in. diameter bolts
• 68 Nnn (50 ft. lbs.) for 7/16 in. diameter bolts
• 47 Nth (35 ft. lbs.) for diesel clutch housing bolts During final transmission installation, install the
shims between the clutch housing and transmission at the appropriate bolt locations.

•

CLUTCH
6 - 5

INDICATOR
PLUNGER
DIAL INDICATOR
CLUTCH
HOUSING
FACE

INDICATOR MOUNTING
„
STUD OR ROD
J9006-29

Fig.
5
Measuring
Clutch
Housing
Face
Runout

+
.009 CLUTCH
HOUSING
FACE

CIRCLE

(AT RIM
OF BORE)
,004

(SAMPLE
READINGS)
J9006-30

Fig.
6
Housing
Face Measurement
Points
And

Sample
Readings

INSTALLATION
METHODS
AND
PARTS
USAGE

Distortion of clutch components during installation
and the use of non-standard components are addi­
tional causes of clutch malfunction.
Improper clutch cover bolt tightening can distort
the cover. The usual result is clutch grab, chatter
CUT/DRILL
BOLT
HOLE
TO SIZE SHIM

STOCK

MAKE
SHIM
1-INCH

DIAMETER
J9006-31

Fig.
7
Housing
Face
Alignment
Shims

and rapid wear. Tighten the cover bolts as described
in the Clutch Service section.
Improperly seated flywheels and clutch housings
are other causes of clutch failure. Improper seating
will produce misalignment and subsequent clutch problems.
Tighten the clutch housing bolts to proper torque
before installing any struts. Also be sure the align­ ment dowels are in place and seated in the block and
housing beforehand.
The use of non-standard or low quality parts can
also lead to problems and wear. Use the recom­
mended factory quality parts to avoid comebacks.

INSPECTION AND DIAGNOSIS CHARTS
The clutch inspection chart (Fig. 8) outlines items
to be checked before and during clutch installation. Use the chart as a check list to help avoid overlook­ing potential problem sources during service opera­

tions.
The diagnosis charts describe common clutch prob­

lems,
causes and correction. Fault conditions are
listed at the top of each chart. Conditions, causes and
corrective action are outlined in the indicated col­

umns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.

6 - 6
CLUTCH

1
Check
clutch
housing bolts.
Tighten
if loose. Be sure

housing
is
fully
seated on engine block.
2 Check
flywheel
condition.
Scuff sand
flywheel
face
to remove glaze. Clean surface
with
a wax and

grease
remover afterward. Replace
flywheel
if
severely scored, worn or cracked. Secure
flywheel

with
new bolts (if removed). Do not reuse old bolts.
Use
Lock and Seal on bolts.

3
Tighten clutch cover bolts 2-3 threads at a
time,
alter­
nately and evenly (in a diagonal
pattern)
to specified
torque. Failure to do so could warp the cover.
4 Check release fork. Replace fork if distorted or worn. Make sure ball stud and release bearing contact sur­

faces
are lubricated.

5
Check release fork pivot. Be sure pivot is tight and ball end is lubricated.
6 Transmission input
shaft
bearing
will
cause noise,
chatter,
or improper release if
damaged.
Check
con­

dition before installing transmission.
7 Inspect release bearing slide surface of trans,
front
bearing
retainer.
Surface should be smooth,
free
of

nicks,
scores.
Replace
retainer
if
necessary.
Lubricate slide surface before installing release bearing. 8 Check input shaft seal if clutch cover and
disc
were

oil covered. Replace seal if worn, or cut.
9 Do not replace release bearing
unless
actually
faulty.
Replace bearing only if seized, noisy, or damaged.
10 Check clutch cover diaphragm spring and release
fingers.
Replace cover if spring or fingers are bent, warped, broken, cracked. Do not tamper
with
fac­

tory
clutch spring setting. Clutch problems
will
result.
11 Check condition of clutch cover. Replace clutch cover if
plate
surface is deeply scored, warped, worn, or
cracked. Be sure cover is correct size and properly
aligned on
disc
and flywheel.
12 Inspect clutch
housing.
Be sure alignment dowels are in position and bolts are tight. Replace housing if
cracked, or damaged. If clutch problems ocurred,
check runout, to be sure housing is square
with

flywheel
and transmission input shaft.
13
Verify
that
housing
alignment dowels are in position before installing
housing.

14 Clean engine block surface before installing clutch
housing.
Dirt, grime can produce misalignment.
15 Make sure side of clutch
disc
marked
"flywheel
side"
is
toward flywheel.
16 Check
rear
main seal if clutch
disc
and cover
were
oil covered. Replace seal if necessary.
17 Check crankshaft flange (if
flywheel
is removed). Be sure flange is clean and
flywheel
bolt threads are
in
good
condition.
18 Check pilot bearing. Replace bearing if dam­
aged.
Lube
with
high temp. Grease before in­
stallation.
19 Check transmission input shaft. Clutch
disc
must slide
freely
on shaft splines. Lightly grease

splines
before installation. Replace shaft if

splines
or pilot bearing hub are damaged.
20 Check
flywheel
bolt torque. If bolts are loose, replace them. Use Mopar Lock and Seal to secure
new bolts.
21 Check clutch
disc
facing. Replace
disc
if facing is charred, scored, flaking off, or worn.
Also
check runout of new
disc.
Runout should not ex­
ceed 0.5 mm (0.02 in.).

J9206-9

Fig. 8 Clutch Inspection Points

CLUTCH
6 - 7
CLUTCH
SLIPS

Condition
Found
Cause
Correction

1.
Disc
facing
worn
out. a) Normal wear.
b) Driver
frequently
"rides"
(slips)
clutch. Results in rapid
wear overheating.
c) Insufficient clutch cover diaphragm spring tension. Replace clutch
disc.
Also
replace
cover if spring is weak or pressure
plate
surface is damaged.
2. Clutch disc facing contaminated
with
oil, grease,
or clutch fluid. a) Leak at
rear
main seal or at

transmission
input shaft seal.
b) Excessive amount of grease applied to input shaft splines.
c) Road
splash,
water
entering
housing.

d) Slave cylinder leaking. a), b), c), d) Replace leaking

seals.
Apply
less
grease to
input shaft splines. Replace
clutch disc (do not clean and reuse). Clean clutch cover and
reuse only if cover is in good
condition. Replace slave
cylinder if leaking.
3. Clutch is running
partially
disengaged.
Release
bearing sticking-binding.

Does
not
return
to normal running

position.
Verify
that
bearing is actually

binding,
then
replace bearing and

transmission
front
bearing
retainer
if sleeve surface is damaged.
4. Flywheel height incorrect. Flywheel surface improperly
machined. Too much stock removed
or surface is tapered. Replace flywheel.
5. Wrong disc or pressure
plate
installed. Incorrect parts order or model
number. Replace
with
correct parts.
Compare old and new parts before installation.
6. Clutch
disc,
cover and/or diaphragm spring, warped,
distorted. a)
Rough
handling (impact) bent
cover, spring, or
disc.

b) Incorrect bolt tightening sequence and method caused
warped cover. Install new disc or cover as needed.
Follow installation/tightening
instructions.
7. Facing on
flywheel
side of disc torn,
gouged,
worn. Flywheel surface scored and nicked.

Reduce
scores and nicks by sanding
or surface grinding. Replace

flywheel
if scores-nicks are deeper
than
.002-.004
inch.
8. Clutch disc facing burnt (charred). Flywheel and cover
pressure
plate
surfaces heavily

glazed.
a) Frequent operation under high

loads
or hard acceleration

conditions.

b) Driver
frequently
"rides"
(slips)
clutch. Results in rapid
wear and overheating of disc and cover.
Scuff
sand flywheel. Replace clutch
cover and
disc.
Alert driver to problem cause.
J9006-21

6
- 8
CLUTCH

IMPROPER CLUTCH
RELEASE

Condition
Found
Cause
Correction

1.
Clutch disc warped. New disc not checked for axial
runout before installation. Replace
disc.
Be sure runout of new

disc
is
less
than .5 mm (.020 in.).
2. Clutch disc binds on input shaft splines. a) Clutch disc hub splines

damaged
during installation.
b) Input shaft splines rough,
damaged.

c) Corrosion, rust formations on
splines
of disc and input shaft.
Clean,
smooth and lubricate disc
and shaft spines. Replace disc
and/or input shaft if splines are
severely damaged.
3. Clutch disc rusted to
flywheel
and/or pressure plate.
Occurs
in vehicles stored, or not
driven for extended periods
of
time.
Also
occurs
after
steam
cleaning if vehicle is not used for extended period.
Remove
clutch cover and
disc.
Sand
rusted surfaces clean
with
180 grit
paper. Replace disc cover, and

flywheel
if corrosion is severe.
4. Clutch disc facing sticks to flywheel.
Vacuum
may form in pockets over

rivet
heads in clutch
disc.
Occurs as
clutch cools down
after
use.
Drill
1/16 inch diameter hole
through rivets and scuff sand disc
facing
with
180J
9r>t
paper.
5. Clutch disc too thick.
Wrong
disc installed. Replace
disc.

6. Pilot bushing seized or loose. a) Bushing cocked during

installation.

b) Bushing defective.
c) Bushing not lubricated.
d) Clutch misalignment. a), b), c), d) Lubricate and install
new bushing. Check and
correct any misalignment.
7. Clutch
will
not disengage properly. a) Low clutch fluid level.
b) Clutch cover loose.
c) Wrong clutch
disc.

d)
Disc
bent, distorted during installation.
e) Clutch cover diaphragm spring bent or wraped during

transmission
instalation.
f) Clutch disc installed
backwards.

g)
Release fork bent or fork pivot
is
loose or damaged.
h) Clutch master or slave cylinder
fault.
a) Top off reservoir and check for

leaks.

b) Tighten bolts.

|
c) Install correct
disc.
d) Repalce
disc.

e) Replace cover.
f) Remove and reinstall disc correctly. Be sure disc side marked "to flywheel" is
actually toward flywheel.

g)
Replace
fork
and pivot if worn or damaged.
h) Replace master and slave cylinder as assembly.
J9006-22

•

CLUTCH
6 - 9 CLUTCH GRAB/CHATTER
Condition
Found
Cause
T

Correction

1.
Clutch
disc
facing covered
with

oil, grease, or clutch fluid. a) Oil leak at
rear
main or input
shaft seal.
b) Too much grease applied to
splines
or
disc
and input shaft. a) Correct leak and replace
disc

(do not clean and reuse the

disc).

b) Apply lighter grease coating to splines and replace
disc
(do not clean and reuse the disc).
2. Clutch
disc
and/or cover warped, or
disc
facings
exhibit
unusual
wear or appear to be
wrong type. Incorrect or substandard parts.
Replace
disc
and/or cover
with

correct parts.
3. Clutch master or slave cylinder plunger dragging-binding. a) Master or slave cylinder
components worn or corroded. a) Replace both cylinders as

assembly
(and reservoir).
4. No
fault
found
with
clutch
components.
a) Problem actually
related
to

suspension
or driveline
component.
b) Engine
related
problem. a)
Further
diagnosis
required.

Check
engine/transmission
mounts,
propeller shafts and U-joints, tires,
suspension

attaching parts and other
driveline components as needed.
b) Check EFI and igniton
systems.

5.
Partial
engagement of clutch
disc
(one side worn-opposite

side
glazed and lightly worn). a) Clutch pressure
plate
position
setting incorrect or modified.
b) Clutch cover, spring, or release fingers bent, distorted (rough
handling,
improper assembly).
c) Clutch
disc
damaged or distorted.
d) Clutch misalignment. a) Replace clutch cover and
disc.

b) Replace clutch cover and
disc.

c) Replace
disc.

d) Check alignment and runout of flywheel,
disc,
or cover and/or clutch
housing.
Correct as
necessary.
J9006-23

6-10
CLUTCH

•
CLUTCH
NOISE

Condition
Found
Cause
Correction

1.
Clutch components damaged or worn out
prematurely.
Incorrect or sub-standard clutch
parts. Replace
with
parts of correct
type

and quality.
2. Pilot bearing damaged. a) Bearing cocked during
installation.
b) Bearing not lubricated prior to installation.
c) Bearing
defect.

d) Clutch misalignment. a), b), c) Replace bearing.

Be
sure it is properly
seated and lubricated

before
installing clutch.
d) Check and correct misalignment caused by
excessive runout of
flywheel,
disc,
cover or clutch
housing.
Replace input shaft if bearing
hub is damaged.
3.
Loose
components. Attaching bolts loose at
flywheel,

cover, or clutch
housing.
Tighten bolts to specified torque.
Replace any clutch bolts
that
are

damaged.

4. Components appear overheated. Hub of
disc

cracked or torsion damper

springs
are distorted or
broken.
Frequent
high load,
full
throttle

operation. Replace parts as needed.
Alert

driver
to condition
causes.

5. Contact surface of release bearing damaged. a) Clutch cover incorrect, or
release fingers are
bent
or
distorted causing damage.
b) Release bearing
defect.

c) Release bearing misaligned. a) Replace clutch cover and
bearing.
b) Replace bearing.
c) Check and correct runout of clutch components. Check
front
bearing
retainer
sleeve surface. Replace if damaged.
6. Release bearing is noisy. Release bearing
defect.
Replace bearing.
7. Clutch pedal squeak. a) Pivot pin loose.
b) Pedal
bushings
worn out or
cracked. Tighten pivot pin. Replace
bushings

if worn or damaged. Lubricate pin
and
bushings
with
silicone base lubricator
chassis
grease.

J9206-10

•

CLUTCH
S - 11
CLUTCH
SERVICE

INDEX

page

Clutch
Cover
and
Disc
Installation—All
11

Clutch
Cover
and
Disc
Removal—All
. 11

Clutch
Housing
Installation
13

Clutch
Housing
Removal
12

Clutch
Linkage
Service
14

CLUTCH
COVER
AND
DISC
REMOVAL—ALL
(1) Raise vehicle.
(2) Remove transmission and remove transfer case
if equipped. Refer to Group 21 for procedures. (3) Remove clutch housing from engine.
(4) Support engine with wood block and adjustable
jack stand (Fig. 1). Supporting engine is necessary to avoid undue strain on engine mounts.

Fig.
1
Supporting
Engine
With
Jack
Stand
And
Wood
Block
(Diesel
Model
Shown)

(5)
If clutch cover will be reused, mark position of
cover on flywheel with paint or scriber (Fig. 2).
(6)
Insert clutch alignment tool in clutch disc and
into pilot bushing. Tool will hold disc in place when
cover bolts are removed.
(7) If clutch cover will be reused, loosen cover bolts
evenly, only few threads at a time, and in a diagonal
pattern (Fig. 3). This relieves cover spring tension evenly to avoid warping.
(8) Remove cover bolts completely and remove
cover, disc and alignment tool.

CLUTCH
COVER
AND
DISC
INSTALLATION
-
ALL
(1) Check runout and free operation of new clutch

disc:
(a) Install disc on transmission input shaft
splines and check fit. Disc should slide freely on
splines.
page

Clutch
Pedal
Installation
17

Clutch
Pedal
Removal
. 15
Flywheel
Service
. 17

Pilot
Bearing
Replacement
14

Release
Bearing
Replacement
13
Fig.
2 Marking
Clutch
Cover
Position

J9106-17

Fig.
3
Clutch
Cover
Bolt
Loosening/Tightening
Pattern

(b) Leave disc on shaft and check disc runout
with dial indicator.