2001 DODGE TOWN AND COUNTRY Service Manual

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Page 249 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (3) Remove the 4 bolts (Fig. 7) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 8).ASSEMBLY
(1) Install the CAB (Fig. 8) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig.

Page 250 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
5). Install the 3 bolts (Fig. 5) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97

INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
5). Install the 3 bolts (Fig. 5) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The ICU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the ICU bracket to the front suspen-
sion crossmember.
(2) Install the ICU and its mounting bracket as an
assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember (Fig. 4). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 3) for the correct chassis brake
tube locations.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the ICU
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 3). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 24-way connector in the
CAB be sure the seal is properly installed in the
connector.(4) Install the 24-way connector (Fig. 1) on the
CAB using the following procedure. Position the
24-way connector in the socket of the CAB and care-
fully push it down as far as possible. When connector
is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 2). This will pull the connec-
tor into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to
the ICU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(5) Clip the cab wiring harness (Fig. 1) to the ICU
mounting bracket.
(6) Install the routing clips (Fig. 9) on the brake
tubes.
(7) Lower the vehicle.
(8) Connect negative cable back on negative post of
the battery.
(9) Bleed the base and ABS hydraulic systems.
Refer to ANTILOCK BRAKE SYSTEM BLEEDING.
(10) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
Fig. 9 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
3 - BRAKE TUBES
4 - ROUTING CLIP
RGBRAKES - ABS5a-13
ICU (INTEGRATED CONTROL UNIT) - RHD (Continued)
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Page 251 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual ProCarManuals.com

Page 252 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION...........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM..............................4
DIAGNOSIS AND TESTING - DRI

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION...........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM..............................4
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT.........................7
DIAGNOSIS AND TESTING - CLUTCH
COVER AND DISC RUNOUT...............7
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS..................7
SPECIAL TOOLS..........................7
CLUTCH RELEASE CABLE - LHD
REMOVAL...............................7
INSTALLATION...........................9
CLUTCH RELEASE LEVER AND BEARING
REMOVAL..............................11INSTALLATION..........................12
MASTER CYLINDER - RHD
REMOVAL..............................13
INSTALLATION..........................14
MODULAR CLUTCH ASSY - 2.4L GAS
REMOVAL..............................14
INSTALLATION..........................15
SLAVE CYLINDER - RHD
REMOVAL..............................15
INSTALLATION..........................15
CLUTCH DISC AND PRESSURE PLATE - 2.5L
TD
REMOVAL..............................15
INSTALLATION..........................15
FLYWHEEL
REMOVAL..............................16
INSTALLATION..........................16
CLUTCH
DESCRIPTION
CLUTCH COMPONENTS
Models equipped with a 2.4L Gas engine utilize a
modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.
Models equipped with the 2.5L Turbo Diesel engine
utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it ishighly
recommended that the clutch cover and disc be
replaced as a set.
Fig. 1 Modular Clutch AssemblyÐ2.4L Gas Engines
1 - MODULAR CLUTCH ASSEMBLY
RGCLUTCH6a-1
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Page 253 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual RELEASE SYSTEM
Left-Hand Drive (LHD) models utilize a cable-actu-
ated clutch release system, consisting of a cable that
connects the clutch pedal to the clutch release lever
in the transaxle (Fig. 3)

Page 254 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual Fig. 4 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 5 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 6 Clutch Master Cylinder (RHD)ÐTypical
1

Page 255 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual DIAGNOSIS AND TESTING - CLUTCH SYSTEM
Clutch problem diagnosis will generally require a
road test to determine the type of fault. Component
inspection will then determine the problem after road
testin

Page 256 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual SERVICE DIAGNOSIS - CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT Normal wear. Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Driver frequently

SERVICE DIAGNOSIS - CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT Normal wear. Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Insufficient clutch cover diaphragm
spring tensionReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASELeak at rear main oil seal or
transaxle input shaft sealReplace leaking seals. Replace modular
clutch assembly (2.4L Gas) or clutch cover
and disc (2.5L TD).
Excessive amount of grease applied
to input shaft splinesApply less grease to input shaft. Replace
modular clutch assembly (2.4L Gas) or
clutch cover and disc (2.5L TD).
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY DISENGAGEDRelease bearing sticking or 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.
Clutch pedal not returning to static
position.Inspect pedal assembly for damage and/or
obstructions. Replace componnents as
necessary.
Cable self-adjuster mechanism (LHD
Models) sticking or binding causing
high preload.Verify that self-adjuster is free to move.
Replace clutch release cable if necessary.
Clutch master cylinder (RHD Models)
or pushrod damaged causing high
preload.Replace clutch master cylinder assembly.
Slave cylinder binding or stuck (RHD
Models).Replace slave cylinder.
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECESLeak at rear main or transaxle input
shaft sealReplace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD)..
Excessive heat from slippage Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
RGCLUTCH6a-5
CLUTCH (Continued)
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