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CLUTCH

TABLE OF CONTENT S

page page

DESCRIPTION AND OPERATION

CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . . 1

CLUTCH HYDRAULIC SYSTEM . . . . . . . . . . . . . . 1

REM OVAL AND IN STALLATION

CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . . 1

PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . 7

SPECIFICATIONS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPECIAL TOOLS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION AND OPERATION

CLUTCH COM PONENTS

The clutch mechanism consists of a single, dry-typecl u t ch d is c a n d a d ia p h r a g m s t yl e cl u t ch cov er . A

h y d r a u li c l in k a g e i s u s e d t o op e r a t e t h e cl u t ch d is c

and cover. The clutch components are very similar to

those used in gas engine models.

A pilot bearing is used to support the transmission

in p u t s h a ft . T h e b e a r in g is s ea t e d i n a s ep a r a t e,

removable h ousing bolted t o t he flywheel hu b.

CLUTCH HYDRAULIC SYSTEM

T h e cl u t ch h y d r a u li c s y st e m s h ou l d n ot r e qu i r e

additional fluid under normal circumsta nces.

NOTE: The reservoir fluid level will actuallyincrease as normal clutch wear occurs. For this rea-son, it is important to avoid over filling, or remov-ing fluid from the reservoir.

If inspection indicates additional fluid is needed,

add fluid from a sealed container only. Use Mopar

brake fluid, or an equivalent meeting standards SAE

J 1703 an d DOT 3. Do not use a ny other type of fluid.

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC

REM OVAL

(1) Remove t he tran smission. Refer to Group 21,

Transmission and Transfer Case for procedure.

(2) If t he original clutch cover will be reinstalled,

mar k position of cover on flywheel for assembly r ef-

erence. Use paint or scribe for this purpose.

(3) If th e clutch cover is t o be r eplaced, cover bolts

can be removed in any sequence. However, if original

cover will be reinstalled, loosen cover bolts evenly in

a star pattern to relieve spring tension equally. This

is n ecessary to avoid warping the cover.

(4 ) R em ove t h e clu t ch cove r b olt s a n d r e m ov e

cover and disc (Fig. 1).

INSTALLATION

(1) Lightly scuff sa nd flywheel face with 180 grit

emery cloth. Then clean surface with brake cleaner.

(2) Light ly lubricate t he pilot bear ing with Mopar

high temperature bearing grease.

Fig. 1 Clutch Cover (Pressure Plate) View1 VEHICLE UNDERBODY

2 ENGINE SPEED SENSOR

3 PRESSURE PLATE RETAINING BOLTS

4 CLUTCH COVER (PRESSURE PLATE)

5 ENGINE OIL PAN


X J CLUTCH 6 - 1

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(3) Check free operation of clutch disc by slidingd is c on t o t r a n s m i s si on ou t p u t s h a ft s p li n es . Dis c

should slide onto splines freely without binding.

(4) Position the clutch disc on flywheel. Be sure

s id e of d is c m a r k e d fl ywh e el s id e i s p os it i on e d

a g a in s t fl ywh e el (F i g. 3 ). I f d i s c i s n ot m a r k e d , b e

s u r e fl a t s id e of d i s c h u b i s p l a ce d t owa r d t h e fl y-

wheel.

(5 ) In s er t t h e clu t ch a lig nm e n t t ool (F i g. 4 ) in

clutch disc and pilot bearing.

(6) Position the clutch cover over the disc an d on

the flywheel (Fig. 5).

(7) Install the clutch cover bolts finger t ight (Fig.

5).

(8) Starting with the bolts marked P on the cover

first, tighten clutch cover bolts in a star pattern to 50

Nm torque (37 ft. lbs.).

(9) Apply l ight coat of Mopar h i gh t e m p er a t u r e

bearing grease to pilot bearing and splines of trans-

mission input shaft .

CAUTION: Do not over-lubricate as this will result

in grease contamination of the disc.

Fig. 2 Clutch Components (VM Diesel)1 ENGINE BLOCK

2 FLYWHEEL

3 CLUTCH HOUSING AND TRANSMISSION

4 CLUTCH COVER

5 CLUTCH DISC

Fig. 3 Clutch Disc Position1 INSPECT THIS SURFACE

2 FLYWHEEL SIDE STAMPED ON THIS SURFACE

6 - 2 CLUTCH X J

REMOVAL AND INSTALLATION (Continued)

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(1 0) I n s t a ll t h e t r a n s m is sion a n d t r a n s fe r ca s e.

Refer to Group 21, Transmission and Tran sfer Case

for p rocedure.

PILOT BEARING

REM OVAL

(1 ) R em ov e t h e t r a n s m i s si on a n d t r a n s fe r ca s e .


for procedures.

(2) Remove t he clutch cover an d disc (Fig. 6). Refer

to clutch cover and disc removal and installation in

this group.

(3 ) Re m ove t h e fou r b ol ts t h a t a t t a ch t h e p ilot

bearing reta iner to t he flywheel (Fig. 7).

(4) Remove th e pilot bearing retainer.

(5 ) S u pp or t t h e b ea r in g r e t a in e r on t w o w ood

blocks.

(6) Remove the pilot bearing with a suitable sizedsocket and extension (Fig. 8). Use mallet to ta p bear-

ing out of retainer.

Fig. 4 Clutch Disc Alignment Typical1 FLYWHEEL

2 CLUTCH COVER AND DISC

3 CLUTCH DISC ALIGNMENT TOOL

Fig. 5 Clutch Cover (Pressure Plate) View

1 VEHICLE UNDERBODY2 ENGINE SPEED SENSOR



5 ENGINE OIL PAN






5 ENGINE OIL PAN


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INSTALLATION

CAUTION: The bearing can be installed incorrectlyif care is not exercised. Make sure the stamped let-ters on the bearing will be facing out (toward rear

of vehicle) after installation.

(1 ) L ig h t ly s cu ff s a n d t h e fl ywh e el s u r fa ce wit h

180 grit emery cloth. Clean the surface with Mopar

brake or carburetor cleaner.

(2) Install the new pilot bearing with hammer and

tool han dle C-4171. (Fig. 9). Seat the bearing flush

with lower edge of chamfer in retainer bore (Fig. 10).Reposition the bearing if necessary.

(3) Install the bearing retainer. Torque bolts to 28

Nm (20 ft. lbs.)

(4) Lubricate the pilot bearing with Mopar high

temperature wheel bearing grease.

Fig. 7 Pilot Bearing Retainer Bolt Removal/Installation

1 RETAINER

2 PILOT BEARING3 FLYWHEEL

Fig. 8 Pilot Bearing Removal1 HOUSING

2 SUITABLE SIZE SOCKET

3 EXTENSION

Fig. 9 Pilot Bearing Installation1 HOUSING

2 SPECIAL TOOL C-4171

3 BEARING

Fig. 10 Pilot Bearing Seated In Retainer1 SEAT PILOT BEARING FLUSH WITH LOWER EDGE OF

CHAMFER (IN BORE)

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(5) Inst all th e clutch disc an d cover (Fig. 11). Refer

to clutch cover and disc removal an d installation in

this group.(6 ) I n st a ll t h e t r a n s m is sion a n d t r a n s fe r ca s e.


for pr ocedur es.

FLYWHEEL

REM OVAL

(1) Remove th e tran smission and clutch housing.


for p rocedure.

(2) Remove t he clutch cover and disc (Fig. 12) as

described in this section.

(3 ) R em ov e t h e b olt s t h a t a t t a ch p il ot b ea r in g

retainer to flywheel.

(4) Remove the pilot bearing and retainer.

(5) Remove th e flywheel bolts.

(6) Gra sp the flywheel firmly and work i t off the

crankshaft flange.

(7) Remove t he o-ring from the crank shaft flange,

or the mounting shoulder of the flywheel (Fig. 14).

(8) Clean the flywheel in solvent.

INSPECTION

E x a m in e t h e fl ywh e el m ou n t i n g s u r fa ce s , cl u t ch

contact surface, and ring gear. Check condition of fly-wh e el h u b a n d a t t a c h in g b ol t s. R ep la ce fl ywh e el i f

h u b e xh ib it s cr a ck s in t h e a r e a of a t t a ch in g b olt

h ol es . R e p la ce r i n g g e a r i f t h e t e et h a r e d a m a g ed .

Resurface the flywheel if the clutch contact surface is

scored or rough (refer to flywheel finishing a nd ring

gear replacement information in this section.

C h eck flyw h ee l r u n ou t if m is a lig n me n t is s u s-

pected. Runout should not exceed 0.08 mm. Measure

flywheel face run out with a dial indicator (Fig. 13).

Mount the indicator on a stud installed in the engine

block or in one of t he flywheel at taching bolt holes.

Face runout can be corrected by resurfacing if neces-

sary. Surface grinding equipment is recommended for

this purpose. Stock removal should not exceed 0.25

m m .

INSTALLATION

CAUTION: Use NEW flywheel bolts for the followingprocedure.

(1 ) C le a n t h e cr a n k s h a ft fl a n ge b efor e m ou n t i n g

t h e fl ywh e el . Di r t or g r ea s e on fl a n ge s u r fa ce m a y

cock flywheel causing run-out.





5 ENGINE OIL PAN






5 ENGINE OIL PAN


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(2 ) I n st a l l n e w o-r i n g i n t h e fl ywh e el m ou n t i n gflange (Fig. 14). Use grease to hold the ring in place.

(3 ) I n st a ll t h e fl yw h ee l on t h e cr a n k s h a ft a n d

align the bolt holes.

(4 ) I n s t a l l a n d t i gh t e n t h e n e w fl ywh e el b ol t s a s

follows:

(a ) Lu b r ica t e a n d in s t a ll t h e 6 n e w fly wh e el

bolts.

(b) Torque the 6 flywheel bolts to 49 Nm (36 ft.

lbs.) starting with one bolt and following with the

opposite one (cross tightening) until completion, in

a clockwise direction (Fig. 15).

(c) Loosen one bolt at a t ime and t ighten to 19.6

Nm (14 ft . lbs.) plus 75 using the cross t ighten-

ing method until completion.

(5) Insta ll the clut ch cover a nd disc (Fig. 16). Refer

to clutch cover and disc removal and installation pro-

cedure in this section.

(6 ) I n st a ll t h e t r a n s m is sion a n d t r a n s fe r ca s e.

Refer to Group 21, Transm ission and Tran sfer Case

for removal and installation procedure.

Fig. 13 Checking Flywheel Runout1 DIAL INDICATOR

2 FLYWHEEL FACE

Fig. 14 Flywheel Mounting (VM Diesel)1 O-RING

2 PILOT BEARING HOUSING

3 FLYWHEEL

4 STARTER RING GEAR

Fig. 15 Cross Tightening Method


2 ENGINE SPEED SENSOR3 PRESSURE PLATE RETAINING BOLTS


5 ENGINE OIL PAN


6 - 6 CLUTCH X J


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FLYWHEEL RING GEAR

REM OVAL

(1 ) R em ov e t h e t r a n s m i s si on a n d t r a n s fe r ca s e .


for removal and installation procedures.

(2 ) R em ov e t h e cl u t ch cov er a n d d is c (F i g. 1 7).

Refer to clutch cover and disc removal and installa-

tion in this group.

(3) Remove t he flywheel. Refer t o flywheel removal

and installation in this group.

(4) Mark position of the old gear for alignment ref-

erence. Use a carbide tipped scribe to mark gear loca-

tion on flywheel.

(5 ) We a r p r ot e ct i ve g og gl es or a p p r ov ed s a fe t yglasses.

(6) Remove the old gear by cutting most of the way

through it at one point. U se an abrasive cut off wheel

f o r t h i s p u r p o s e . B r e a k t h e r i n g g e a r a t c u t wi t h a

hammer and a cold chisel or punch

(7) Ring gear is shrink fit on flywheel. This means

t h e ge a r m u s t b e e xp a n de d b y h e a t in g in or d er t o

install i t .

NOTE: The method of heating and expanding thenew ring gear is extremely important. Every surfaceof the gear must be heated at the same time to pro-duce uniform expansion. An oven or similarenclosed heating device must be used. Temperature

required for uniform expansion is approximately

350-375.

CAUTION: Do not use an oxy/acetylene torch toremove the old gear, or to heat and expand a new

gear. The high temperature of the torch flame cancause 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 thegear teeth resulting in rapid wear and damage afterinstallation.

INSTALLATION(1) Position and install the heated ring gear on the

flywheel:

(a) Wear heat resistant gloves to handle the hot

ring gear.

(b) Align the ring gear on the flywheel evenly.

( c ) Us e h a m m e r a n d b r a s s d r i f t t o t a p r i n g g e a r

onto the flywheel.

(d) Seat the ring gear on flywheel

(2) Allow t he ring gear to cool down before insta l-

lation on the engine. P lace flywheel on work bench

and let i t cool in normal shop air.

(3) Install the flywheel and torque bolts. Refer toflywheel removal and installation in this group.

(4) Insta ll the clut ch cover a nd disc (Fig. 18). Refer

to clutch cover and disc removal and installation in

this group.

(5 ) I n st a ll t h e t r a n s m is sion a n d t r a n s fe r ca s e.


for removal and installation procedures.

CAUTION: Do not use water or compressed air to

cool the flywheel. The rapid cooling produced bywater or compressed air will distort or crack thenew gear.





5 ENGINE OIL PAN


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SPECIFICATIONS

SPECIFICATIONS

D ES CRIP TION TORQU E

C lu t c h C o v e r t o F l y w h e e l

Bolts . . . . . . . . . . . . . . . . . . . 50 Nm (37 ft . lbs.)C l ut c h H o us i ng t o T r a ns m i s s i o n

Bolts . . . . . . . . . . . . . . . . . . . 46 Nm (34 ft . lbs.)

F l y w h e e l t o C r a n k s h a ft

Bolts . . . . . See removal and installation procedure.

Pi l o t B e a r i ng R e t a i ne r t o Fl y w he e l / C r a nks ha f t

Bolts . . . . . . . . . . . . . . . . . . . 28 Nm (20 ft . lbs.)

C lu t c h H o u s i n g t o E n g i n e

Top (2) Bolts . . . . . . . . . . . . . . 37 Nm (27 ft. lbs.)

Middle (2) Bolts . . . . . . . . . . . 58 Nm (43 ft. lbs.)

Bottom (2) Bolts . . . . . . . . . . . 75 Nm (55 ft. lbs.)

SPECIAL TOOLS

SPECIAL TOOLSFig. 18 Clutch Cover (Pressure Plate) View

1 VEHICLE UNDERBODY




5 ENGINE OIL PAN


Universal HandleC-4171

6 - 8 CLUTCH X J


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