Dodge ram truck 3500 1996 Service Manual page 268

6 - 6 CLUTCH —
DIAGNOSIS AND TESTING (Continued)
B R
1 Check clutch housing bolts. Tighten if loose. Be sure
housing is fully seated on engine block.
2 Check flywheel. Scuff sand face to remove glaze.
Clean surface with wax and grease remover.
Replace flywheel if severely scored, worn or
cracked. Secure flywheel with new bolts (if
removed). Do not reuse old bolts. Use Mopar Lock
N'Seal on bolts.
3 Tighten clutch cover bolts 2-3 threads at a time,
alternately and evenly (in a star pattern) to
specified torque. Failure to do so could warp the
cover.
4 Check release fork. Replace fork if bent or worn.
Make sure pivot and bearing contact surfaces are
lubricated.
5- Check release fork pivot (in housing). Be sure pivot
is secure and ball end is lubricated.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release i f damaged. Check
condition before installing transmission.
7 'Check slave cylinder. Replace it if leaking. Be sure
cylinder is properly secured in housing and cylinder
piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc were
oil covered. Replace seal if worn, or cut.
9
Inspect release bearing slide surface of trans, front
bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary.
Lubricate slide-surface before installing release
bearing.
10 Do not replace release bearing unless actually
faulty. Replace bearing only if seized, noisy, or
damaged.
11 Check clutch cover diaphragm' spring and release •
fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with
factory spring setting as clutch problems will result.
12 Check condition of clutch cover. Replace clutch
cover if plate surface is deeply scored, warped,
worn, or cracked. Be sure cover is correct size and
properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.
Replace housing if damaged.
14 Verify that housing alignment dowels are in position
before installing housing.
15 Clean engine block surface before installing clutch
housing. Dirt, grime can produce misalignment.
16 Make sure side of clutch disc marked "flywheel
side" is toward flywheel.
17 Check rear main seal if clutch disc and cover were
oil covered. Replace seal if necessary.
18 Check crankshaft flange (if flywheel is removed). Be
sure flange is clean and flywheel bolt threads are in
good condition.
19 Check pilot bearing. Replace bearing if damaged.
Lube with Mopar high temp, bearing grease before
installation.
20 .Check transmission input shaft. Disc must slide freely
on shaft splines. Lightly grease splines before
installation. Replace shaft if splines or pilot bearing
hub are damaged.
21 Check flywheel bolt torque. If bolts are loose,
replace them. Use Mopar Lock N'Seal to secure new
bolts.
22 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed 0.5
mm (0.02 in.).
J9506-2
Fig. 9 Clutch Inspection Points