chrysler dakota part5

7/28/2019 chrysler dakota part5

1/16

CLUTCH

CONTENTS

page page

CLUTCH COMPONENT SERVICE . . . . . . . . . . . . 10CLUTCH DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 15

GENERAL INFORMATION

INDEX

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Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 1Clutch Disc Application . . . . . . . . . . . . . . . . . . . . . . 1Clutch Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 1

Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 2Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . 2Hydraulic Clutch Linkage . . . . . . . . . . . . . . . . . . . . . 1

CLUTCHCOMPONENTSThe clutch mechanism in AN models consists of a

single, dry-type clutch disc and a diaphragm style

clutch cover.

A sleeve-type release bearing is used to engage and

disengage the clutch cover pressure plate. The bear-

ing is prelubricated during manufacture and is a

sealed unit.

The release bearing is operated by a pivoting re-lease fork in the clutch housing. The fork pivots on a

ball stud within the housing. The release fork is ac-

tuated by a hydraulic slave cylinder. The slave cylin-

der is operated by a clutch master cyli nder connected

to the clutch pedal.

The clutch disc has cushion springs in the disc hub.

The clutch disc facing is riveted to the hub. The fac-

ing is made from a non-asbestos material.

The clutch cover pressure plate is a diaphragm

type unit with a one-piece diaphragm spring and

multiple release fingers. The pressure plate release

fingers are preset during manufacture and are not

adjustable.

The transmission input shaft is supported in the

crankshaft by a pilot bearing.

CLUTCH DISC APPLICATIONA 232 mm (9.13 in.) diameter clutch disc and cover

are used for 2.5L (I4) engine applications.

A 265 mm (10.4 in.) diameter clutch disc and cover

are used for 3.9L (V6) engine applications.

A 280 mm (11.02 in.) diameter clutch disc and

cover are used for 5.2L (V8) engine applications.

HYDRAULIC CLUTCH LINKAGEA hydraulic linkage is used to operate the clutch

release fork and bearing. T he linkage consists of a re-

mote fluid reservoir, a clutch master cylinder, clutch

slave cylinder, and interconnecting fluid lines.

The master cylinder is connected to the clutch

pedal. The slave cylinder is connected to the clutch

release fork. The clutch master cylinder is mounted

on the drivers side of the dash panel next to thebrake booster.

The clutch master cylinder push rod is connected

directly to the clutch pedal.

The hydraulic linkage is serviced as an as-

sembly only. The individual components that

form the linkage assembly cannot be over-

hauled or serviced separately.

CLUTCH HYDRAULIC FLUIDThe clutch hydraulic linkage cylinders and lines

are prefilled with fluid at the factory.

The hydraulic system should not require additional

flui d under normal circumstances. I n fact, the reser-

voir fluid level will actually increase as normal

clutch wear occurs. For this reason, it is impor-

tant to avoid overfilling, or removing fluid from

the reservoir.

I f inspection or diagnosis indicates additional fluid

may be needed, use M opar brake fluid, or an equiv-

alent meeting SAE J 1703 and DOT 3 standards. Do

not use any other type of fluid.

CLUTCH 6 - 1


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CLUTCH LUBRICATIONPr oper clutch component lubrication is important

to satisfactory operation. Using the correct lubricantand avoiding over lubrication are also equally impor-tant.

During service, apply r ecommended l ubricant spar-ingly. Do not overlubricate as this could result in

clutch disc and pressure plate contamination.Clutch and transmission components requiring lu-

brication are: pilot bearing release lever pivot ball stud release lever pivot surfaces release bearing bore clutch pedal pivot bore and bushings. transmission input shaft splines and pilot hub release bearing slide surface of front bearing re-tainer

Do not apply grease to any part of the clutch

cover or disc.

Use Mopar multi mileage grease or a silicone

grease for the clutch pedal bushings and pivot shaft.

Use Mopar high temperature bearing grease orequivalent for the pilot bearing, release bearing bore,transmission input shaft and release fork compo-

nents. Apply recommended amounts only and do notoverlubricate. Refer to the Clutch Service section forspecific information.

CLUTCH PEDAL POSITIONSWITCHA clutch pedal position switch has been added to

the starter circuit. The switch, which is in circuitwith the starter solenoid, requires that the clutchpedal be fully depressed in order to start the engine.Switch circuitry and operation is provided in section8W of Group 8.

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CLUTCH DIAGNOSIS

INDEX

page page

Clutch Cover and Disc Runout . . . . . . . . . . . . . . . . 4Clutch Housing Misalignment . . . . . . . . . . . . . . . . . 4Clutch Misalignment . . . . . . . . . . . . . . . . . . . . . . . . 3Clutch Problem Causes . . . . . . . . . . . . . . . . . . . . . 3

Flywheel Misalignment . . . . . . . . . . . . . . . . . . . . . . 3General Information . . . . . . . . . . . . . . . . . . . . . . . . 3Improper Clutch Release or Engagement . . . . . . . . . 3Inspection and Diagnosis Charts . . . . . . . . . . . . . . . 4

GENERAL INFORMATIONProblem diagnosis will generally require a road

test to determine the type of fault. Component in-

spection will then determine the problem cause after

road testing.

Drive the vehicle at normal speeds during the road

test. Shift the transmission through all gear ranges

and observe clutch action.

I f chatter, grab, slip, or improper release is experi-enced, remove and inspect the clutch components.

However, if the problem is noise or hard shifting, fur-

ther diagnosis may be needed. The transmission or

another driveline component may actually be at

fault. Careful observation during the test will help

narrow the problem area.

CLUTCH PROBLEM CAUSES

CONTAMINATION

Fluid contamination is a frequent cause of clutch

malfunctions. Oil, grease, water, or other fluids on

the clutch contact surfaces will cause faulty opera-

tion. The usual result is chatter, slip and grab.

During inspection, note if any components are con-

taminated. L ook for evidence of oil , grease, clutch hy-

draulic fluid, or water/road splash on clutch

components.

Oil contamination indicates a leak at either the

rear main seal or transmission input shaft. Oil leaks

produce a residue of oil on the housing interior and

on the clutch cover and flywheel. Heat buildup

caused by slippage between the cover, disc and fly-

wheel, can sometimes bake the oil residue onto the

components. The glaze-like residue ranges in colorfrom amber to black.

Road splash contamination means dirt/water is en-

tering the clutch housing. This may be due to l oose

bolts, housing cracks, or through the slave cylinderopening. Driving through deep water puddles canforce water/road splash into the housing throughsuch openings.

Clutch fluid leaks are from loose or damaged clutchlinkage fluid lines or connections. However, mostclutch flui d l eaks will usually be noted and correctedbefore severe contamination occurs.

Grease contamination is usually a product of exces-

sive lubrication during clutch service. Apply only a

small amount of grease to the i nput shaft splines,

bearing retainer, pilot bearing, release fork and pivot

stud. E xcess grease can be thrown off during opera-

tion and contaminate the disc.

CLUTCH MISALIGNMENT

Clutch components must be i n proper alignmentwith the crankshaft and transmission input shaft.

Misalignment caused by excessive runout or warpage

of any clutch component will cause grab, chatter and

improper clutch release.

IMPROPER CLUTCH RELEASE OR ENGAGEMENTClutch release or engagement problems are caused

by wear, or damage to one or more clutch compo-nents. A visual inspection of the release componentswill usually reveal the problem part.

Release problems can result in hard shifting andnoise. Items to look for are: leaks at the clutch cylin-

ders and interconnecting line; loose slave cylinderbolts; worn/loose release fork and pivot stud; dam-aged release bearing; and a worn clutch disc, or pres-sure plate.

A uni que release problem involves vehicles that arestored or out of service for long periods of time. Nor-mal condensation can generate enough corrosion tomake the disc stick to the flywheel, or pressure plate.I f this condition is experienced, correction only re-quires that the disc be loosened manually throughthe inspection plate opening.

Engagement problems usually result in slip, chat-ter/shudder, and noisy operation. The primary causes

are clutch disc contamination; clutch disc wear; mis-alignment, or distorti on; flywheel damage; or a com-bination of the foregoing. A visual inspection isrequired to determine the part actually causing theproblem.

FLYWHEEL MISALIGNMENTCommon causes of misalignment are heat warping,

mounting the fl ywheel on a dirty crankshaft flange,incorrect bolt tightening, improper seating on thecrankshaft flange shoulder, or loose crankshaft or fl y-wheel bolts.

CLUTCH 6 - 3


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Very light scoring on the flywheel face can becleaned up by scuff sanding with 120/180 grit emerycloth or sandpaper. However, the flywheel should bereplaced if warped, or severely scored. Do not ma-chine the flywheel. The flywheel face i s manu-factured with a unique surface contour.Machining would negate this feature resulting

in unsatisfactory operation.Clean the crankshaft flange before mounting theflywheel. Dirt and grease on the flange surface maycock the flywheel causing excessive runout. Use newbolts when remounting a flywheel and secure thebolts with Mopar L ock And Seal. Tighten flywheelbolts to specifi ed torque only. Overtightening can dis-tort the fl ywheel hub causing runout.

CLUTCH COVER AND DISC RUNOUTCheck the clutch disc before installation. Axial

(face) runout of a new disc should not exceed 0.5 mm(0.020 in.). Measure runout about 6 mm (1/4 in.) from

the outer edge of the disc facing. Obtain another discif runout is excessive.

Check condition of the clutch before i nstallation. Awarped cover or diaphragm spring will cause graband incomplete release or engagement. Be carefulwhen handli ng the cover and disc. I mpact can distortthe cover, diaphragm spring, release fi ngers and thehub of the clutch disc.

Use an alignment tool when positioning the disc onthe flywheel. The tool prevents accidental misali gn-ment which could result in cover distortion and discdamage.

A frequent cause of clutch cover distortion is im-

proper bolt tightening. To avoid warping the cover,the bolts must be tightened i n a diagonal pattern andonly 2-3 threads at a time to the specifi ed torque.

CLUTCH HOUSINGMISALIGNMENTClutch housing alignment is important to proper

clutch operation. The housing bore maintains align-ment between the crankshaft and transmission inputshaft.

Misalignment can cause noise, incomplete clutchrelease and chatter. I t can also result in prematurewear of the pilot bearing, cover release fingers andclutch disc. I n severe cases, misalignment can alsocause premature wear of the transmission inputshaft and the shaft bearing.

The most frequent causes of housing misalignmentare incorrect seating on the engine or transmission,

loose housing bolts, missing alignment dowels, or

housing damage. Only rarely is misalignment caused

by housing mounting surfaces that are not parallel.

I f housing misali gnment is suspected, the housing

is probably not fully seated on either the engine,

alignment dowels, or transmission front face. Since

the AX 15 and NV3500 clutch housings are either at-

tached, or an i ntegral part of the transmission gearcase, it will be necessary to remove the transmission

and housing as an assembly to check seating.

Be sure the housing mounting surface is clean. Also

be sure the housing alignment dowels are securely in

place in the engine block and are in good condition.

Replace the dowels if distorted, damaged, or doubt

exists about dowel condition.

CLUTCH INSTALLATION METHODS AND

PARTS USAGE

Distortion of clutch components during installation

or using non-standard components are additional

causes of clutch malfunction.

I mproper clutch cover bolt tightening can distort

the cover. The usual result is clutch grab, chatter

and rapid wear. Tighten the cover bolts as described

in Clutch Service section.

I mproperly seated flywheels and clutch housings

are other causes of clutch failure. I mproper seating

will produce misalignment and clutch problems.

Tighten all the clutch housing bolts to proper torque

before installing any struts. Also be sure alignment

dowels are in place and seated i n the block and hous-

ing before bolt tightening.

The use of non-standard or low quality parts canalso lead to problems and wear. Use the recom-

mended factory quality parts to avoid comebacks.

INSPECTION AND DIAGNOSIS CHARTSThe clutch inspection chart outlines items to be

checked before and during clutch installation. Use

the chart as a check list to help avoid overlooking po-

tential problem sources during service operati ons.

The diagnosis charts describe common clutch prob-

lems, causes and correction. Fault conditions are

li sted 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 refer-

ence when diagnosing faulty clutch operation.

6 - 4 CLUTCH


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CLUTCH INSPECTION CHART

CLUTCH 6 - 5


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CLUTCH SLIPS

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IMPROPER CLUTCH RELEASE

CLUTCH 6 - 7


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CLUTCH GRAB/CHATTER

6 - 8 CLUTCH


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CLUTCH NOISE

CLUTCH 6 - 9


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CLUTCH COMPONENT SERVICE

INDEX

page page

Clutch Cover and Disc Installation . . . . . . . . . . . . . 10Clutch Cover and Disc Removal . . . . . . . . . . . . . . 10Clutch Housing Replacement (AX 15) . . . . . . . . . . 11Clutch Hydraulic Linkage Installation . . . . . . . . . . . 13Clutch Hydraulic Linkage Removal . . . . . . . . . . . . . 12

Clutch Pedal Installation . . . . . . . . . . . . . . . . . . . . 13Clutch Pedal Removal . . . . . . . . . . . . . . . . . . . . . . 13Flywheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . 13Pilot Bearing Replacement . . . . . . . . . . . . . . . . . . 12Release Bearing Replacement . . . . . . . . . . . . . . . 12

CLUTCH COVER AND DISC REMOVAL

(1) Raise vehicle.

(2) Remove transmission and clutch housing as as-

sembly. Refer to Group 21 for procedures.

(3) I f clutch cover is only being removed for access

to another component, mark position of cover on fly-

wheel with small punch marks (Fig. 1).

(4) L oosen clutch cover bolts evenly and in rotation

to r eli eve spring tension. L oosen bolts a few threads

at a time only to avoid warping cover. This is espe-

cially important if cover will be reused.(5) Completely remove cover bolts, clutch cover and

clutch disc (Fig. 2).

CLUTCH COVER AND DISC INSTALLATION(1) Clean flywheel surface with solvent. Scuff sand

surface with 120/180 grit emery cloth to remove mi-nor scratches and glazing.

(2) Check runout and free operation of new clutchdisc. I nstall disc on transmission input shaft splines.Disc should slide freely on splines. L eave disc onshaft and check runout with a dial indicator. Position

indicator plunger about 6 mm (1/4 in.) from outeredge of facing. Runout should not exceed 0.5 mm(0.020 in.). Obtain another clutch disc if runout ex-ceeds specified limit.

(3) L ubricate crankshaft pilot bearing with Moparhigh temperature bearing grease or equivalent.

(4) I nsert clutch alignment tool or spare inputshaft in clutch disc.

(5) Verify that disc hub is positioned correctly. Sideof hub marked Flywheel Side should face flywheel

(Fig. 3).(6) I nsert alignment tool or spare input shaft i n pi-

lot bearing and position disc on flywheel (Fig. 4).(7) Position clutch cover over disc and on flywheel.(8) I nstall all clutch cover bolts finger tight.(9) Tighten cover bolts evenly (and in rotation) a

few threads at a time. Cover bolts must be tight-ened evenly and to specified torque to avoiddistorting cover. Tighten 2.5L bolts to 28 Nm (250 in. lbs.) Tighten 5/16 in. diameter bolts to 23 Nm (17 ft.lbs.)

Fig. 1 Typical Method Of Marking Clutch CoverPosition

Fig. 2 Clutch Components (2.5L Shown)

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Tighten 3/8 i n. diameter bolts to 41 Nm (30 ft.

lbs.)

(10) Apply light coat of Mopar high temperature

bearing grease to splines of transmission input shaftand to release bearing slide surface of front bearing

retainer. Do not overlubricate shaft splines. This

could result in grease contamination of disc.

(11) I nstall transmission and clutch housing as as-

sembly. Refer to procedures in Group 21.

CLUTCH HOUSINGREPLACEMENT (AX 15)(1) Raise vehicle and remove transmission and

clutch housing as assembly. Refer to procedure inGroup 21.

(2) Remove release bearing, release fork and fork

boot.

(3) Remove bolts attaching clutch housing to trans-

mission (Fig. 5).

(4) Clean mounting surfaces of transmission and

replacement clutch housing. Use a wire brush if nec-

Fig. 4 Typical Method Of Aligning Clutch Disc

Fig. 5 Clutch Housing Attachment (AX 15)

Fig. 3 Clutch Disc Position

CLUTCH 6 - 11


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essary followed by a wax and grease remover, or sim-

il ar solvent. Al so clean engine block surface as well.

(5) Position replacement clutch housing on trans-

mission and i nstall housing attaching bolts. Tighten

bolts to 38 Nm (28 ft. lbs.) torque.(6) Transfer release fork pivot ball stud to replace-

ment housing if necessary.

(7) L ubricate release bearing bore, release forkcontact surfaces and release fork pivot stud with Mo-par high temperature bearing grease. Also lubricatetransmission i nput shaft splines, pilot hub and bear-ing retainer slide surface with light coat of samegrease.

(8) I nstall release fork and bearing in housing. Besure release fork boot is properly seated in housing.

(9) I nstall transmission as described in Group 21.

RELEASEBEARINGREPLACEMENT(1) Remove transmission as described in Group 21.(2) Disconnect release bearing from fork and re-

move bearing (Fig. 6).(3) I nspect release bearing slide surface of trans-

mission front bearing retainer. Replace retainer ifslide surface is scored, worn or cracked.

(4) I nspect release fork and fork pivot (Fig. 6). Besure pivot is secure and in good condition. Be surefork is not distorted or worn. Replace release fork re-tainer spring if bent or damaged i n any way.

(5) L ightly lubricate pilot bearing, input shaftspli nes, bearing retainer slide surface, fork pivot andrelease fork pivot surface with Mopar high tempera-ture bearing grease.

(6) I nstall release fork and bearing. Be sure fork

and bearing are properly secured.(7) I nstall transmission and clutch housing.

Tighten transmission and clutch housing bolts tospecifications indicated in Figure 4.

PILOTBEARINGREPLACEMENT(1) Remove transmission and clutch housing.(2) Remove clutch cover and disc.

(3) Remove pilot bearing. Use blind hole puller

tools such as those included in Snap-On set CG40CB

to remove bearing.

(4) Clean bearing bore with solvent and wipe dry

with shop towel.

(5) L ubricate new pilot bearing with Mopar high

temperature grease.

(6) Position and start new bearing i n bearing boreby hand. Note that pilot bearing has seal at one

end. I nstall bearing so seal is facing outward

toward transmission.

(7) Seat pilot bearing with clutch alignment tool

(Fig. 7). Keep bearing straight during installa-

tion. Do not allow bearing to become cocked.

Tap bearing into place until flush with edge of

bearing bore. Do not recess bearing.

(8) I nstall transmission assembly.

CLUTCH HYDRAULIC LINKAGE REMOVALThe clutch master cylinder, remote reservoir,

slave cylinder and connecting lines are ser-

viced as a complete assembly. The linkage com-

ponents cannot be overhauled or servicedseparately. The cylinders and connecting lines

are sealed units.

(1) Raise vehicle.

(2) Remove nuts attaching slave cylinder to clutch

housing.

(3) Remove slave cylinder and clip from housing.

(4) Remove hydraulic fluid line from body clips.

(5) L ower vehicle.

(6) Carefully remove retaining clip from clutch

master cylinder mounting bracket (Fig. 8).

Fig. 6 Release Bearing And Release Fork Mounting

Fig. 7 Typical Method Of Installing Pilot Bearing

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(7) Remove retaining ring, flat washer and wave

washer that attach clutch master cylinder push rod

to clutch pedal (Fig. 8).

(8) Slide clutch master cylinder push rod off clutch

pedal pin.

(9) I nspect condition of bushing on clutch pedal

pin. Remove and replace bushing if worn or dam-

aged.(10) Verify that cap on clutch master cylinder res-

ervoir is ti ght. This is necessary to avoid undue spill-

age during removal.

(11) Remove screws attaching clutch fluid reservoir

to dash panel.

(12) Pull clutch master cylinder rubber seal from

dash panel (Fig. 8).

(13) Rotate clutch master cylinder 45 counter-

clockwise to unlock it. Then remove cylinder from

dash panel.

(14) Remove hydraulic linkage components from

vehicle.

CLUTCH HYDRAULIC LINKAGE INSTALLATION(1) Tighten cap on clutch fluid reservoir to avoid

spillage during installation.(2) Position cylinders, connecting lines and reser-

voir in vehicle.(3) I nsert clutch master cylinder in dash panel. Ro-

tate cylinder 45 clockwise to lock it in place.(4) L ubricate master cylinder rubber seal with liq-

uid dish soap to ease installation. Then seat seal indash and around cylinder.

(5) Position reservoir on dash panel and install

reservoir screws. Tighten screws to 5 N m (40 in. l bs.)torque.

(6) I nstall replacement bushing on clutch pedal pinif necessary.

(7) I nstall clutch master cylinder push rod onclutch pedal pin. Secure rod with wave washer, flatwasher and retainer ring.

(8) I nstall retaining clip i n clutch master cylindermounting bracket.

(9) Raise vehicle.(10) I nsert slave cylinder push rod through clutch

housing opening and i nto release lever. Be sure capon end of rod is securely engaged in release lever.

Check this before installing cylinder attaching nuts.(11) I nstall and tighten slave cylinder attaching

nuts to 23 Nm (200 in. lbs.) torque.(12) I nsert clutch fluid l ine in body clips and lower

vehicle. Verify that fluid line from master cylin-der to slave cylinder is properly routed and se-cured in retaining clips on dash panel.

CLUTCH PEDAL REMOVAL(1) Remove retaining ring, flat washer and wave

washer securing push rod on clutch pedal (Fi g. 8).(2) Slide push rod off clutch pedal pin.

(3) I nspect bushing on the clutch pedal pin. Re-

place bushing if worn or damaged.

(4) Remove snap ring and washer attaching clutch

pedal to the pivot shaft.

(5) Slide pedal off pivot shaft and remove pedal.

(6) Remove and inspect bushings in pedal bore. Re-

place bushings if worn or cracked.

CLUTCH PEDAL INSTALLATION(1) L ubricate pedal bushings and shaft with a sili-

cone grease or with Mopar multi mileage grease.

(2) I nstall bushings in pedal bore and on pin.

(3) I nstall pedal on pivot shaft.

(4) Secure pedal on shaft with washer and snap

ring.

(5) Connect push rod to pedal and secure rod with

wave washer, flat washer and retaining ring.

FLYWHEEL SERVICE

I nspect the flywheel whenever the clutch disc andcover are removed for service. Check condition of the

flywheel face, hub, starter ring gear teeth, and fly-

wheel bolts.

Minor scratches, burrs, or glazing on the flywheel

face can be reduced with 120/180 grit emery cloth.

However, the fl ywheel should be replaced if the disc

contact surface is severely scored, heat checked,

cracked, or obviously worn.

Cleanup of minor flywheel scoring should be per-

formed with surface grinding equipment. Remove

only enough material to reduce scoring (approximate-

ly 0.001 - 0.003 in.).

Heavy stock removal is not recommended.

The flywheel surface is manufactured with a

unique contour which can be damaged by ma-

chining. Replace the flywheel if scoring is se-

vere and deeper than 0.076 mm (0.003 in.).

Excessive stock removal can also result in fly-

wheel cracking or warpage after installation. It

can also weaken the flywheel and interfere

with proper clutch release.

Check flywheel runout if misalignment is sus-

pected. Runout should not exceed 0.08 mm (0.003

in.). Measure runout at the outer edge of the fly-

wheel face with a dial indicator. M ount the dial indi-cator on a stud installed in place of one of the

flywheel attaching bolts.

Clean the crankshaft flange before mounting theflywheel. Dirt and grease on the flange surface maycock the flywheel causing runout.

Check condition of the flywheel hub and attachingbolts. Replace the fl ywheel if the hub exhibits cracksin the area of the attaching bolt holes.

I nstall new attaching bolts whenever the fl ywheelis replaced. Apply Mopar L ock-N-Seal, or L octite 242on the replacement bolt threads before installation.

CLUTCH 6 - 13


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Recommended for V6 and V8 engine fl ywheel boltsis 75 Nm (55 ft. lbs.). R ecommended torque for 2.5Lflywheel bolts is 95 Nm (70 ft. lbs.).

I nspect the teeth on the starter ring gear. If theteeth are worn or damaged, the flywheel shouldbe replaced as an assembly. T his is the recom-mended and preferred method of repair.

I n cases where a new flywheel is not readily avail-able, a replacement ring gear can be installed. How-ever, the following precautions must be observed toavoid damaging the flywheel and replacement gear.

(a) Mark position of the old gear for alignmentreference on the flywheel. Use a scriber for thispurpose.

(b) Wear protective goggles or approved safetyglasses. Also wear heat resistent gloves when han-

dling a heated ring gear.(c) Remove the old gear by cutting most of the

way through it (at one or two points) with an abra-sive cut-off wheel. Then complete removal with acold chisel or punch.

(d) The ring gear is a shrink fit on the fly-wheel. This means the gear must be expandedby heating in order to i nstall it. The methodof heating and expanding the gear is ex-tremely important. E very surface of the gearmust be heated at the same time to produceuniform expansion. An oven or similar en-

closed heating device should be used. Temper-

ature required for uniform expansion is 149-

177C (300-350F).

CAUTION: Never use an oxy/acetylene torch to re-

move the old ring gear, or to heat and expand a re-

placement gear. The high temperature of the torch

flame will cause localized heating and damage the

flywheel. In addition, using the torch to heat a re-

placement gear will cause uneven heating and ex-

pansion. The torch flame will also anneal the gear

teeth resulting in rapid wear and damage after in-

stallation.

(e) Be sure to wear eye and hand protection.

Heat resistent gloves and protective goggles are

needed for personal safety. Also use metal tongs,vise grips, or similar tools to position the gear as

necessary for installation.

(f) Allow the flywheel and ring gear assembly to

cool down before installation. Set the assembly on a

workbench and let it cool to shop air temperature.

CAUTION: Do not use water, or compressed air to

cool the ring gear or flywheel. The rapid cooling

produced by water or compressed air will distort, or

crack the gear and flywheel.

Fig. 8 Clutch Pedal And Hydraulic Linkage Components

6 - 14 CLUTCH


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SPECIFICATIONS

TORQUE SPECIFICATIONS

CLUTCH 6 - 15


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