
INTRODUCTION 
INTRODUCTION 
DESIGNATIONS,
 LABELS/PLATES/DECALS, 
 CODES
 AND DIMENSIONS/WEIGHTS . 
 CONTENTS 
page 
 MEASUREMENT
 AND TORQUE 
... 1 SPECIFICATIONS 
 page 
. 11 
DESIGNATIONS, LABELS/PLATES/DECALS, CODES
 AND
 DIMENSIONS/WEIGHTS 
 INDEX 
page 
Engine
 and
 Transmission/Transfer
 Case 
 Identification
 2 
Engine/Transmission/GVWR
 4 
Equipment
 Identification
 Plate
 3 
 International
 Vehicle Control
 and
 Display 
 Symbols
 10 
Major Component
 Identification 3 
VEHICLE DESIGNATIONS  The Vehicle Code chart lists description and code 
for Ram Truck and Sport Utility vehicles. The codes  are used to identify vehicle types in charts, captions 
and in service procedures. The vehicle codes are
 dif
ferent than the Vehicle Identification Number (VIN)  or the wheelbase/model code. 
VEHICLE SAFETY CERTIFICATION
 LABEL 
 A certification label is attached to the left side 
B-pillar. The label certifies that the vehicle conforms 
to Federal Motor Vehicle Safety Standards (FMVSS). 
The label also lists the:  • Month and year of vehicle manufacture 
• Gross Vehicle Weight Rating (GVWR). The gross 
front and rear axle weight ratings (GAWR's) are 
based on a minimum rim size and maximum cold tire  inflation pressure  Vehicle Identification Number (VIN) 
Type of vehicle 
Type of rear wheels (single or dual)  Bar code 
Month, Day and Hour (MDH) of final assembly 
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE  The Vehicle Identification Number (VIN) plate is 
attached to the top left side of the instrument panel. 
The VIN contains 17 characters that provide data 
concerning the vehicle. Refer to the decoding chart to 
determine the identification of a vehicle. 
 page 
Trailer
 Towing Specifications
 4 
Vehicle Code Plate
 2 
Vehicle Designations
 1 
Vehicle Dimension
 4 
Vehicle
 Identification
 Number (VIN) Plate
 1 
Vehicle Safety
 Certification
 Label
 ............. 1 
Vehicle Weights
 4 
VEHICLE CODE
 DESIGNATIONS 
 VEHICLE CODE
 = AD
 (DODGE
 RAM 
PICKUP
 &
 CHASSIS
 CAB) 
VEHICLE 
FAMILY LINE  DESCRIPTION 
AD1
 D150 
AD2
 D250 
AD3
 D350 
 PICKUP 
4x2 
AD5
 W150 
 AD6
 W250 
AD7
 W350 
 PICKUP 
4x4 
AD2
 D250 
 AD3
 D350 
 CHASSIS
 CAB 
4x2 
AD6
 W250 
 AD7
 W350 
 CHASSIS
 CAB 
4x4 
AD4
 AD100 
AD4
 AD150 
 SPORT
 UTILITY 
4x2 
AD8
 AD100 
AD8 AD
 150 
 SPORT
 UTILITY 
4x4 
J90IN-32   

FRONT SUSPENSION
 AND
 AXLE
 2 - 3 
FRONT
 WHEEL
 ALIGNMENT 
GENERAL
 INFORMATION 
 Front wheel alignment involves
 the
 correct posi
tioning
 of the
 tire contact patch
 in
 relation
 to the 
pavement.
 The
 positioning
 is
 accomplished through 
the suspension
 and
 steering linkage adjustments.
 An 
 alignment
 is
 essential
 for
 efficient steering
 and
 direc
tional stability.
 The
 most important factors
 of
 front 
end alignment
 are
 camber, caster
 and toe
 position.  Routine inspection
 of
 the front
 suspension
 and 
steering components
 is a
 good
 preventative 
maintenance practice.
 Inspection
 also
 helps
 to 
 ensure
 safe operation
 of the
 vehicle. 
• CAMBER
 is the
 number
 of
 degrees
 the top of the 
wheel
 is
 tilted either inward
 or
 outward.
 An
 excessive 
negative camber angle will cause tread wear
 at the in
 side
 of
 the tire.
 An
 excessive positive camber angle will 
cause tread wear
 at the
 outside
 of
 the tire (Fig.
 1), 
 • CASTER
 is the
 number
 of
 degrees
 of
 forward
 or 
rearward tilt
 of the
 steering knuckles. Forward tilt 
provides
 a
 negative caster angle. Rearward tilt pro vides
 a
 positive caster angle
 (Fig. 1). 
• WHEEL
 TOE
 POSITION
 is the
 difference between 
the leading
 and
 trailing inside edges
 of the
 front 
tires (Fig.
 1).
 Incorrect wheel
 toe
 position
 is the
 most  common cause
 of
 unstable steering
 and
 steering  wheel off-center.
 The
 wheel
 toe
 position
 is the
 final 
front wheel alignment adjustment.  • STEERING AXIS INCLINATION ANGLE
 is
 mea
sured
 in
 degrees
 and is the
 angle that
 the
 steering 
knuckles
 are
 tilted (Fig. 1).
 The
 inclination angle
 has 
a fixed relationship with
 the
 camber angle. This will 
not change except when
 a
 spindle
 or
 ball stud
 is 
damaged
 or
 bent.
 The
 angle
 is not
 adjustable
 and the 
damaged component(s) must
 be
 replaced
 to
 correct 
mis-alignment. 
CAUTION:
 Do not
 attempt to modify
 any
 suspension 
or steering
 component
 by
 heating
 and
 bending. 
PRE-ALIGNMENT INSPECTION 
 Before starting
 a
 front wheel alignment,
 the
 follow
ing inspection
 and
 necessary corrections must
 be 
 completed. 
 (1)
 Tires with
 the
 same recommended
 air
 pressure, 
size,
 and
 tread wear. Refer
 to
 Group
 22,
 Wheels
 and 
Tires
 for
 diagnosis information.  (2) Front wheel bearings
 for
 wear
 or
 adjustment. 
(3) Ball studs
 and
 linkage pivot points, steering 
gear
 for
 looseness, roughness, binding
 or a
 sticking 
condition. Refer
 to
 Group
 19,
 Steering
 for
 additional  information. 
 CASTER 
POSITIVE CASTER 
 STEERING
 WHEEL CENTER 
i 0.5
 CCW 
0
 5
 CW 
CCW
 =
 COUNTER CLOCKWISE 
CW
 -
 CLOCKWISE 
 CAMBER 
NEGATIVE CAMBER (SHOWN) 
TOP
 OF
 WHEEL INBOARD 
POSITIVE CAMBER
 (NOT
 SHOWN) 
TOP
 OF
 WHEEL OUTBOARD 
 NOMINAL-PREFERRED 
THE NOMINAL VALUE
 IS 
THE
 PREFERRED
 VALUE 
LEFT/RIGHT
 DIFFERENCE 
THE VALUE
 Of
 THE LEFT SIDE 
MINUS THE VALUE
 OF
 THE 
RIGHT SIDE 
EX. 
If
 FT CASTER
 - +6 5 
RIGHT
 CASTER
 »
 +8.0 
LEFT/RIGHT DIFFERENCE 
65 8.0
 =
 1
 5 
 TOE 
NEGATIVE TOE (TOE
 OUT)
 B>A 
POSITIVE TOE (TOE
 IN) 6
 FRONT
 Of
 VEHICLE 
 ft 
 THRUST
 ANGLE 
ANGLE
 OF
 REAR
 AXLE RELATIVE
 TO
 VEHICLE CENTERUNE 
(+)
 AXLE POINTS LEFT
 (-)
 AXLE POINTS RIGHT 
PRODUCTION
 TOLERANCE 
THE RANGE
 Of
 ACCEPTABLE 
VALUES
 AROUND THE NOMINAL 
-
 PREFERRED  PRODUCTION
 +6.5A7.5 
PREFERRED:
 +7.0 
TOLERANCE:
 0.5 
 J9302-61 
Fig.
 1
 Wheel
 Alignment
 Measurements   

• 
FRONT
 SUSPENSION
 AND
 AXLE
 2 - 11 (2) Position the seal over the ball stud (if neces
sary, use a replacement seal). Force portion of the 
seal downward on the ball stud housing with an ap
propriate size socket wrench until it is securely  locked in place. 
(3) Install lower suspension arm using procedure 
under Lower Suspension Arm Installation. 
LOWER SUSPENSION
 ARM
 BUSHING 
REMOVAL  (1) Follow procedure under Coil Spring and Lower 
Suspension Arm Removal. 
(2) Use an arbor press and an appropriate size 
sleeve to force the original bushing from the lower 
suspension arm bore. 
INSTALLATION  (1) Use an arbor press and an appropriate size 
sleeve to force the replacement bushing into the 
lower suspension arm bore. Ensure that it is com
pletely seated in the bore. 
(2) Install the lower suspension arm according to in
structions provided within the installation procedure. 
UPPER SUSPENSION
 ARM REMOVAL  (1) Raise the vehicle. Position support stands un
der the frame rail and lower the front of the hoist. 
Remove the wheel/tire. 
(2) Remove shock absorber, refer to above proce
dures. 
(3) Install Spring Compressor DD-1278 (Fig. 5). 
Tighten the nut finger-tight and then loosen it 1/2 of- a-turn. 
(4) Remove the cotter pins and the ball stud nuts. 
(5) Install Ball Stud Remover C^3564-A (Fig. 8). 
Turn the threaded portion of the tool to lock it se curely against the upper ball stud (Fig. 8). Spread 
the tool enough to apply force against the upper ball  stud. Strike the steering knuckle sharply with a 
hammer to loosen the upper ball stud. Do not at
tempt to force the ball stud out of the steering  knuckle bore with the loosening tool. 
(6) Remove the loosening tool. Remove the nuts, 
eccentric (cam) bolts and suspension arm from the 
vehicle (Fig. 9). 
INSTALLATION  (1) Position the suspension arm and install the ec
centric (cam) bolts (Fig. 9). and nuts finger-tight. 
(2) Install upper ball stud into steering knuckle. 
Install nuts on the ball studs. Tighten to 142 N« (105 
ft. lbs.) torque. Install replacement cotter pins. 
(3) Remove the spring compressor tool (Fig. 5). 
 Fig.
 8
 Ball
 Stud
 Loosening
 Tool Installed 
(4) Install the shock absorber. Tighten nut to 34 
N*m (25 ft. lbs.) torque and lower bolts to 23 N*m  (200 in. lbs.) torque. 
(5) Install the wheel/tire. Raise the vehicle, remove 
the support stands and lower the vehicle to the surface. 
(6) Adjust the caster and camber angles. Tighten 
the eccentric (cam) nuts to 95 N*m (70 ft. lbs.) 
torque. 
UPPER BALL STUD 
INSPECTION  (1) Position a floor jack under the lower suspension 
arm. Raise the wheel and allow the tire to lightly 
contact the floor (vehicle weight relieved from the 
tire). 
(2) Grasp the top of the tire and apply force in and 
out. Look for any movement at the ball joints be
tween the upper suspension arm and steering  knuckle. 
(3) If any lateral movement is evident, replace the 
ball joint. 
REMOVAL  (1) Position a support under the outer end of the 
lower suspension arm. Lower the vehicle so that the 
support compresses the coil spring. 
(2) Remove the wheel/tire. 
(3) Remove the ball stud nuts. Use Ball Stud Re
mover C-3564-A to loosen the upper ball stud (Fig. 
8). 
 (4) Use Wrench C-3561 to un-thread the upper ball 
stud from the upper suspension arm.   

• 
BRAKES
 5 - 43 
CAMPER
 ASSEMBLY 
(1) Mount caliper in vise equipped with protective 
jaws.
 Do not overtighten vise. Excessive pressure  could cause bore distortion and piston binding.  (2) Lubricate new piston seal and piston bore with 
fresh brake fluid.  (3) Install new piston seal in bore groove (Fig. 15). 
Position seal in one area of groove and gently work it  around and into remainder of groove until seated. Be 
sure seal is not twisted or rolled over. 
Fig.
 15 Installing Caliper
 Piston
 Seal 
(4) Lubricate new dust boot with fresh brake fluid 
and install it in caliper (Fig. 16). Work boot into 
groove with fingers. Boot will seem larger than 
groove diameter at first but will snap into place 
when properly positioned. 
(5) Plug fluid inlet port and install bleeder screw. (6) Coat caliper piston with brake fluid. 
(7) Start piston into dust boot and bore (Fig. 16). 
Spread dust boot with fingers. Then work piston 
through boot and into bore. Air trapped below piston 
will force boot around it and into groove as piston is  installed. 
(8) Remove plug from inlet port and loosen bleeder 
screw. 
(9) Carefully press piston into bore with turning 
motion until fully bottomed. Apply force uniformly to  avoid cocking piston (Fig. 16). 
(10) Seat dust boot with suitable size installer tool 
if necessary. 
CALIPER
 INSTALLATION 
 (1) Install brakeshoes in caliper and adapter. 
 Fig.
 16 Installing Caliper
 Piston 
(2) Connect brake hose to brake line on frame 
bracket. Tighten hose fitting to 13-20 N«m (115-175  in. lbs.) torque. 
(3) Connect brake hose to caliper. Use new seal 
washers when connecting fitting to caliper. Do not 
tighten hose fitting at this time. 
(4) Lubricate caliper and adapter slide surfaces 
with Mopar high temperature grease, or an equiva lent grease. 
(5) Install and secure caliper in adapter. 
(6) Fill master cylinder and bleed brakes. 
(7) Install wheel and tire assemblies and lower ve
hicle. 
ROTOR INSPECTION AND
 SERVICE 
ROTOR
 CONDITION 
 Rotor condition and tolerances can be checked with 
the rotor mounted on the axle. However, wheel bear ing end play should be reduced to zero before check
ing lateral runout. 
The rotor braking surfaces should not be machined 
unless actually necessary. Light surface rust and  scale can be removed in a lathe equipped with dual 
sanding discs. 
Worn, or scored rotor surfaces can be restored by 
machining in a disc brake lathe but only if surface  scoring and wear are light. 
The rotor should be replaced if: 
• severely scored 
• tapered 
• has hard spots 
• cracked 
• warped 
• too thin 
• machining would cause rotor thickness to fall be
low minimum thickness requirements   

5
 - 48
 BRAKES 
• 
Fig.
 6
 Brakeshoe
 Installation 
 (8) Install cable guide in secondary shoe and posi
tion cable in guide.  (9) Assemble adjuster screw (Fig. 7). Then install 
and engage adjuster screw in brakeshoes. 
CAUTION:
 Be sure the
 adjuster
 screws
 are in
stalled
 on the
 correct
 brake unit. The
 adjuster 
screws
 are marked L
 (left)
 and R
 (right)
 for
 identifi
cation
 (Fig. 8).  ' WASHER SOCKET
 STAMPED
 LETTER 
BUTTON
 NUT
 RH227A 
Fig.
 7 Adjuster
 Screw
 Components 
 (10) Install adjuster lever and spring and connect 
adjuster cable to lever. 
(11) Install secondary shoe retainers and spring. 
(12) Install shoe spring. Connect spring to second
ary shoe first. Then to primary shoe.  (13) Verify adjuster operation. Pull adjuster cable 
upward. Cable should lift lever and rotate start 
wheel. Be sure adjuster lever properly engages start 
wheel teeth. 
(14) Adjust brakeshoes to drum with brake gauge. 
Refer to Service Adjustments section for procedure. 
BRAKE
 DRUM
 INSPECTION
 AND
 REFINISHING 
 BRAKE DRUM REFINISHING  The brake drums can be resurfaced on a drum 
lathe when necessary. Initial machining cuts should 
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in) at a 
time as heavier feed rates can produce taper and sur face variation. Final finish cuts of 0.025 to 0.038 mm 
(0.001 to 0.0015 in.) are recommended and will gen
erally provide the best surface finish. 
Be sure the drum is securely mounted in the lathe 
before machining operations. A damper strap should  always be used around the drum to reduce vibration 
and avoid chatter marks. 
BRAKE DRUM REFINISH LIMITS  The maximum allowable diameter of the drum 
braking surface is stamped or cast into the drum  outer edge (Fig. 8). Generally, a drum can be ma
chined to a maximum of 1.52 mm (0.060 in.) oversize. 
Always replace the drum if machining would cause 
drum diameter to exceed indicated size limit. 
 Fig.
 8 Location Of Brake
 Drum
 Maximum Allowable 
Diameter  BRAKE DRUM RUNOUT 
Measure drum diameter and runout with an accu
rate gauge. The most accurate method of measure
ment involves mounting the driim in a brake lathe 
and checking variation and runout with a dial indi
cator. Variations in drum diameter should not exceed 
0.076 mm (0.003 in.). Drum runout should not exceed  0.20 mm (0.008 in.) out of round. Refinish the drum 
if runout or variation exceed these values. 
BRAKE
 DRUM
 INSTALLATION 
 (1) Clean drum with Mopar brake cleaning solvent 
or with a soap and water solution only. Do not use  any other cleaning agents and do not use compressed 
air to remove dirt and dust.   

5
 - 54
 BRAKES 
• (11) Attach adjuster cable to adjuster lever. Be 
sure cable is properly routed. 
(12) Adjust brakeshoes to drum with brake gauge. 
BRAKE
 DRUM INSTALLATION 
 (1) Position drum on axle housing. 
(2) Install bearing and inner nut. Adjust bearing 
as described in Group 3.  (3) Install locking washer and outer nut. Bend 
locking washer to secure it.  (4) Place new gasket on hub and install axle shaft, 
cones,
 lock washers and nuts.  (5) Install wheel and tire assembly. 
(6) Remove support stands and lower vehicle. 
BRAKE
 DRUM
 SERVICE 
 BRAKE DRUM REFINISHING  The brake drums can be resurfaced on a drum 
lathe when necessary. Initial machining cuts should 
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a  time as heavier feed rates can produce taper and sur
face variation. Final finish cuts of 0.025 to 0.38 mm  (0.001 to 0.0015 in) are recommended and will gen
erally provide the best surface finish. 
Be sure the drum is securely mounted in the lathe 
before machining operations. A damper strap should  always be used around the drum to reduce vibration 
and avoid chatter marks. 
BRAKE DRUM REFINISH LIMITS  The maximum allowable diameter of the drum 
braking surface is stamped or cast into the drum  outer edge (Fig. 9). Generally, a drum can be ma
chined to a maximum of 1.5 mm (0.060 in.) oversize. 
Always replace the drum if machining would cause 
drum diameter to exceed indicated size limit. 
BRAKE DRUM RUNOUT  Measure drum diameter and runout with an accu
rate gauge. The most accurate method of measure
ment involves mounting the drum in a brake lathe  and checking variation and runout with a dial indi
cator. 
Variations in drum diameter should not exceed 
0.076 mm (0.003 in). Drum runout should not exceed 
0.20 mm (0.008 in.) out of round. Refinish the drum 
if runout or variation exceed these values. 
WHEEL
 CYLINDER REMOVAL 
 (1) Raise and support vehicle. 
(2) Remove brake drum and brakeshoes as de
scribed in this section.  (3) Remove anchor bolt and nut and remove 
washer, spring, parking brake lever, adjuster cable,  cam plate and anchor pin bushing.  (4) Loosen brakeline at wheel cylinder. 
(5) Remove wheel cylinder bolts.  Fig. 9 Location Of Brake
 Drum
 Maximum Allowable 
Diameter  (6) Disconnect brakeline and remove wheel cylin
der. 
WHEEL
 CYLINDER OVERHAUL 
WHEEL CYLINDER DISASSEMBLY  (1) Remove push rods and boots (Fig. 10). 
(2) Press pistons, cups and spring and expander 
from cylinder bore.  (3) Remove bleed screw. 
Fig.
 10
 Wheel
 Cylinder
 Components 
CLEANING AND INSPECTION  Clean the cylinder and pistons with clean brake 
fluid or brake cleaner only. Do not use any other  cleaning agents. Dry the cylinder and pistons with 
compressed air. Do not use rags or shop towels to dry 
the cylinder components. Lint from such materials  can adhere to the cylinder bores and pistons.   

• 
CLUTCH
 6 - 3 Check condition of the clutch before installation. A 
warped cover or diaphragm spring will cause grab  and incomplete release or engagement. 
Be careful when handling the cover and disc. Im
pact can distort the cover, diaphragm spring, release 
fingers and the hub of the clutch disc. 
Use an alignment tool when positioning the disc on 
the flywheel. The tool prevents accidental misalign ment which could result in cover distortion and disc 
damage. 
A frequent cause of clutch cover distortion (and 
consequent misalignment) is improper bolt tighten
ing. To avoid warping the cover, tighten the bolts al
ternately (in a diagonal pattern) and evenly (2-3 
threads at a time) to specified torque. 
Clutch
 Housing
 Misalignment And Runout  Clutch housing alignment is important to proper 
operation. The housing bore maintains alignment be
tween the crankshaft and transmission input shaft. 
Misalignment can cause noise, incomplete clutch 
release and chatter. It can also result in premature 
wear of the pilot bearing, cover release fingers and 
clutch disc. In severe cases, misalignment can also  cause premature wear of the transmission input 
shaft and bearing. 
Housing face misalignment is generally caused by 
incorrect seating on the engine or transmission, loose 
housing bolts, missing alignment dowels or housing  damage. Infrequently, misalignment may also be 
caused by housing mounting surfaces that are not 
parallel.  If housing misalignment is suspected, housing bore 
and face runout can be checked with a dial indicator 
as described in the following two procedures: 
MEASURING
 CLUTCH HOUSING BORE 
RUNOUT 
 (1) Remove the clutch housing and strut. 
(2) Remove the clutch cover and disc. 
(3) Replace one of the flywheel bolts with a 7/16-20 
threaded rod that is 10 in. (25.4 cm) long (Fig. 1). 
The rod will be used to mount the dial indicator. 
(4) Remove the release fork from the clutch hous
ing.  (5) Reinstall the clutch housing. Tighten the hous
ing bolts nearest the alignment dowels first.  (6) Mount the dial indicator on the threaded rod 
and position the indicator plunger on the surface of 
the clutch housing bore (Fig. 2). 
(7) Rotate the crankshaft until the indicator 
plunger is at the top center of the housing bore. Zero  the indicator at this point. 
(8) Rotate the crankshaft and record the indicator 
readings at eight points (45° apart) around the bore  (Fig. 3). Repeat the measurement at least twice for 
accuracy.  (9) Subtract each reading from the one 180° oppo
site to determine magnitude and direction of runout. 
Refer to Figure 3 and following example. 
Bore runout example: 0.000 - (-0.007) = 0.007 in.  + 0.002 - (-0.010) = 0.012 in. 
+ 0.004 - (-0.005) = 0.009 in. 
-0.001 -
 (
 + 0.001) = -0.002 in. (= 0.002 inch) 
In the above example, the largest difference is 
0.012 in. and is called the total indicator reading 
 (TIR).
 This means that the housing bore is offset 
from the crankshaft centerline by 0.006 in. (which is  1/2 of 0.012 in.). 
On gas engines, the acceptable maximum TIR for 
housing bore runout is 0.010 inch. If measured TIR is  more than 0.010 in. (as in the example), bore runout 
will have to be corrected with offset dowels. Offset  dowels are available in 0.007, 0.014 and 0.021 in. 
sizes for this purpose (Fig. 4). Refer to Correcting 
Housing Bore Runout for dowel installation. 
On diesel engines, the acceptable maximum 
TIR for housing bore runout is 0.015 inch. How
ever, unlike gas engines, offset dowels are not  available to correct runout on diesel engines. If 
bore runout exceeds the stated maximum on a  diesel engine, it may be necessary to replace ei
ther the clutch housing, or transmission adapter 
plate. 
CORRECTING CLUTCH HOUSING BORE 
RUNOUT
 (GAS
 ENGINE
 ONLY) 
 On gas engine vehicles, clutch housing bore runout 
is corrected with offset dowels. However, if bore 
runout exceeds 0.015 in. TIR on a diesel equipped  model, the clutch housing, or transmission adapter 
plate may have to be replaced. Offset dowels are not available for diesel models. 
The dial indicator reads positive when the plunger 
moves inward (toward indicator) and negative when  it moves outward (away from indicator). As a result, 
the lowest or most negative reading determines the 
direction of housing bore offset (runout). 
In the sample readings shown in Figure 3 and in 
step (7) above, the bore is offset toward the 0.010 
inch reading. To correct this, remove the housing and 
original dowels. Then install the new offset dowels in 
the direction needed to center the bore with the  crankshaft centerline. 
In the example, TIR was 0.012 inch. The dowels 
needed for correction would have an offset of 0.007 
in. (Fig. 4). 
Install the dowels with the slotted side facing out 
so they can be turned with a screwdriver. Then in
stall the housing, remount the dial indicator and 
check bore runout again. Rotate the dowels until the 
TIR is less than 0.010 in. if necessary. 
If a TIR of 0.053 in. or greater is encountered, it 
may be necessary to replace the clutch housing.   

• 
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.