2002 DODGE RAM Service Repair Manual

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Page 241 of 2255

DODGE RAM 2002 Service Repair Manual (3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 11). The rod will be used to mount the dial
indicator.
(4) Remove release fork from the

(3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 11). The rod will be used to mount the dial
indicator.
(4) Remove release fork from the clutch housing.
(5) Install clutch housing. Tighten the housing
bolts nearest the alignment dowels first.
(6) Mount dial indicator on the threaded rod and
position indicator plunger on the clutch housing bore
(Fig. 12).
(7) Rotate crankshaft until indicator plunger is at
the topof the housing bore. Zero the indicator at this
point.(8) Rotate crankshaft and record indicator read-
ings at eight points (45É apart) around the bore (Fig.
13). Take measurement at least twice for accuracy.
(9) Subtract each reading from the one 180É oppo-
site to determine runout and direction. Bore runout
example (Fig. 13):
²0.000 ± (±0.007) = 0.007 in.
²+0.002 ± (±0.010) = 0.012 in.
²+0.004 ± (±0.005) = 0.009 in.
²±0.001 ± (+0.001) = ±0.002 in.
In this example the largest or total indicator read-
ing (TIR) difference is 0.012 inch. This means the
housing bore is offset from the crankshaft centerline
by 0.006 in. which is 1/2 of 0.012 inch. The dowels
needed to correct this have an offset of 0.007 in. (Fig.
14).
Remove housing and install dowels with the slotted
side facing out so they can be turned with a screw-
driver. Then install the housing and mount the dial
indicator and check bore runout again. Rotate the
dowels until the TIR is less than 0.010 inch.
Clutch Housing Face Runout
(1) Position dial indicator towards the housing face
(Fig. 15) with indicator plunger on the rim of the
housing bore.
(2) Rotate crankshaft until indicator plunger is at
the 10 O'clock position and zero the dial indicator.
(3) Measure and record face runout readings at
four points 90É apart (Fig. 16). Take measurement at
least twice for accuracy.
(4) Subtract lowest reading from highest to deter-
mine total runout. If low reading wasminus0.004
in. and highest reading wasplus0.009 in. the total
runout is 0.013 inch.
NOTE: Maximum acceptable face runout is 0.010
inch.
Fig. 11 Dial Indicator Mounting Stud Or Rod
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
Fig. 12 CLUTCH HOUSING BORE RUNOUT
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
Fig. 13 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING BORE CIRCLE
6 - 10 CLUTCHBR/BE
CLUTCH HOUSING (Continued)

Page 242 of 2255

DODGE RAM 2002 Service Repair Manual To correct this example (Fig. 16) the shims needed
between the clutch housing and transmission are:
²0.009 in. at the 0.000 corner
²0.012 in. at the ±0.003 corner
²0.013 in. at the ±0.004 corner

Page 243 of 2255

DODGE RAM 2002 Service Repair Manual (3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Lubricate release fork and pivot contact sur-
faces with Mopar High Temperature wheel b

(3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Lubricate release fork and pivot contact sur-
faces with Mopar High Temperature wheel bearing
grease or equivalent before installation.
(5) Align and install clutch housing on transmis-
sion (Fig. 19). Tighten housing bolts closest to align-
ment dowels first and to the following torque values:
²1/4in. diameter ªAº bolts - 4.5 N´m (40 in.lb.).
²3/8in. diameter ªAº bolts - 47.5 N´m (35 ft.lb.).
²7/16in. diameter ªAº bolts - 68 N´m (50 ft.lb.).
²ªBº bolts for 5.2L/5.9L applications - 41 N´m (30
ft.lb.).
²ªBº bolts for 5.9L TD/8.0L applications - 47.5
N´m (35 ft.lb.).
²ªCº bolts for 5.2/5.9L applications - 68 N´m (50
ft.lb.).
²ªCº bolts for 5.9L TD applications - 47.5 N´m (35
ft.lb.).
²ªCº bolts for 8.0L applications - 74.5 N´m (55
ft.lb.).
(6) Install transmission-to-engine strut after
installing clutch housing. Tighten bolt attaching
strut to clutch housing first and engine bolt last.
(7) Install the starter to the clutch housing.
(8) Install the clutch housing dust shield to the
clutch housing. Tighten the bolts to
(9) Install transmission and transfer case, if
equipped. Refer to 21Transmission and Transfer Case
for proper procedures.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case forprocedures.
(2) Remove clutch housing, for NV4500 equipped
vehicles.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 20).
INSTALLATION
NOTE: Inspect bearing slide surface on transmis-
sion front bearing retainer. Replace retainer if slide
surface is scored, worn or cracked. Inspect release
lever and pivot stud. Be sure stud is secure and in
good condition. Be sure fork is not distorted or
worn. Replace fork spring clips if bent or damaged.
(1) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud and release lever
pivot surface with Mopar high temperature bearing
grease or equilvalent.
Fig. 18 Transmission/Clutch Housing - NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
Fig. 19 Clutch Housing Installation - NV4500
1 - ENGINE BLOCK
2 - CLUTCH DISC AND COVER
3 - CLUTCH HOUSING
4 - DUST COVER
6 - 12 CLUTCHBR/BE
CLUTCH HOUSING (Continued)

Page 244 of 2255

DODGE RAM 2002 Service Repair Manual (2) Install release fork and release bearing (Fig.
21) and verify fork and bearing are secured by spring
clips. Also be sure that the release fork is installed
properly.
NOTE: The rear side of the rel

(2) Install release fork and release bearing (Fig.
21) and verify fork and bearing are secured by spring
clips. Also be sure that the release fork is installed
properly.
NOTE: The rear side of the release lever has one
end with a raised area. This raised area goes
toward the slave cylinder side of the transmission.
(3) Install clutch housing, if removed.(4) Install transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case for procedures.
FLYWHEEL
DIAGNOSIS AND TESTING - FLYWHEEL
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DISASSEMBLY
NOTE: If the teeth are worn or damaged, the fly-
wheel should be replaced as an assembly. This is
the recommended repair. In cases where a new fly-
wheel is not readily available, (V10/Diesel Engine
only) a replacement ring gear can be installed. The
following procedure must be observed to avoid
damaging the flywheel and replacement gear.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES WHILE CUTTING RING GEAR.
Fig. 20 Clutch Release Components
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N´m (200 IN. LBS.)
6 - SPRING
Fig. 21 Clutch Release Fork
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
BR/BECLUTCH 6 - 13
CLUTCH RELEASE BEARING (Continued)

Page 245 of 2255

DODGE RAM 2002 Service Repair Manual (1) Mark position of the old gear for alignment ref-
erence on the flywheel. Use a scriber for this pur-
pose.
(2) Remove the old gear by cutting most of the way
through it (at one point) with an abra

(1) Mark position of the old gear for alignment ref-
erence on the flywheel. Use a scriber for this pur-
pose.
(2) Remove the old gear by cutting most of the way
through it (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or
punch.
ASSEMBLY
NOTE: The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it. The method of heating and
expanding the gear is extremely important. Every
surface of the gear must be heated at the same
time to produce uniform expansion. An oven or
similar enclosed heating device must be used. Tem-
perature required for uniform expansion is approxi-
mately 375É F.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES AND HEAT RESISTENT GLOVES
WHEN HANDLING A HEATED RING GEAR.
(1) The heated gear must be installed evenly to
avoid misalignment or distortion.
(2) Position and install the heated ring gear on the
flywheel with a shop press and a suitable press
plates.
(3) Place flywheel on work bench and let it cool in
normal shop air. Allow the ring gear to cool down
completely before installation it on the engine.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air will distort or crack the
new gear.
PILOT BEARING
REMOVAL
(1) Remove transmission, transfer case, if
equipped and clutch housing. Refer to 21 Transmis-
sion and Transfer Case for procedures.
(2) Remove pressure plate and disc.
(3) Using a suitable blind hole puller to remove
pilot bearing.
INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 22). Keep bearing straight and tap bearing into
place until flush with edge of bearing bore. Do not
recess bearing.
(3) Install clutch cover and disc.
(4) Install clutch housing, transmission and trans-
fer case, if equipped. Refer to 21 Transmission and
Transfer Case for procedures.
Fig. 22 Installing Pilot Bearing
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
6 - 14 CLUTCHBR/BE
FLYWHEEL (Continued)

Page 246 of 2255

DODGE RAM 2002 Service Repair Manual CLUTCH PEDAL
REMOVAL
(1) Remove knee bolster for access to pedal pivot
shaft.
(2) Remove brake lamp switch.
(3) Remove retaining clips that secure the brake
and clutch pedals to the push rods (Fig. 23

Page 247 of 2255

DODGE RAM 2002 Service Repair Manual (5) Remove the plastic clip securing the hydraulic
line to the dash panel from the upper dash panel
stud.
(6) Lower vehicle.
(7) Disconnect clutch pedal interlock switch wires.
(8) Remove retaining cl

(5) Remove the plastic clip securing the hydraulic
line to the dash panel from the upper dash panel
stud.
(6) Lower vehicle.
(7) Disconnect clutch pedal interlock switch wires.
(8) Remove retaining clip (Fig. 26).
(9) Slide clutch master cylinder push rod off pedal
pin.
(10) Inspect condition of bushing in the clutch
master cylinder pushrod (Fig. 26). Replace the clutch
hydraulic linkage if bushing is worn or damaged.
(11) Verify that cap on clutch master cylinder res-
ervoir is tight. This will avoid spillage during
removal.
(12) Remove the nuts holding the clutch master
cylinder to the dash panel.
(13) Remove screws that attach clutch fluid reser-
voir to dash panel.
(14) Remove the clutch master cylinder from the
dash panel.
(15) Remove clutch cylinders, reservoir and con-
necting lines from vehicle.
INSTALLATION
NOTE: The factory installed hydraulic linkage has a
quick disconnect at the slave cylinder, this fitting
should not be disconnected. The hydraulic linkage
is serviced as an assembly only, but it comes as
two pieces to ease installation. Once the clutch
hydraulic line is connected to the slave cylinder, it
should not be disconnected.
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser-
voir in vehicle engine compartment. Locate the clutch
hydraulic line against the dash panel and behind all
engine hoses and wiring.
(3) Insert clutch master cylinder in dash panel.
Install and tighten the nuts to hold the clutch master
cylinder to the dash panel.
(4) Apply a light coating of grease to the inside
and outside diameter of the master cylinder bushing.
(5) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with retaining clip.
(6) Connect clutch pedal position (interlock) switch
wires.
Fig. 25 Hydraulic Clutch Linkage
1 - DASH PANEL
2 - CYLINDER RESERVOIR
3 - CLUTCH MASTER CYLINDER
4 - SLAVE CYLINDER
5 - CLUTCH HYDRAULIC LINE
Fig. 26 Clutch Cylinder Push Rod Attachment
1 - PIN
2 - CLUTCH INTERLOCK WIRE
3 - PUSH ROD
4 - CLIP
6 - 16 CLUTCHBR/BE
LINKAGE (Continued)

Page 248 of 2255

DODGE RAM 2002 Service Repair Manual (7) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N´m
(40 in. lbs.).
(8) Install the plastic clip securing the hydraulic
line to the dash panel into

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