Dodge ram truck 3500 1996 Service Manual page 270

6 - 8 CLUTCH
D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d )
CONTINUED
B R
CONDITION POSSIBLE CAUSES
CORRECTION
CLUTCH DISC WARPED
1. New disc not checked for axial
. runout before installation.
1. Replace disc. Be sure runout of new
disc is less than .5 mm (.020 in.).
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINES
1. Clutch disc hub splines
damaged during installation.
Input shaft splines rough,
damaged. Corrosion, rust
* formations on splines of disc
and input shaft.
1. Clean, smooth and lubricate disc and
shaft splines. Replace disc and/or input
shaft if splines are severely damaged.
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE
1. Occurs in vehicles stored,
or not driven for extended
periods of time. Also occurs
after steam cleaning if vehicle
is not used for extended period.
1. Remove clutch cover and disc. Sand
rusted surfaces clean with 180 grit paper.
Replace disc cover, and flywheel if
corrosion is severe.
CLUTCH DISC FACING
STICKS TO FLYWHEEL
1. Vacuum may form in pockets
over rivet heads in clutch disc.
Occurs as clutch cools down
after use.
1. Drill 1 /16 inch diameter hole through
rivets and scuff sand disc facing with 180
grit paper.
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED,
LOOSE, OR ROLLERS
ARE WORN
1. Bearing cocked during
installation. Bearing defective.
Bearing not lubricated. Clutch
misalignment.
1. Lubricate and install new bearing.
Check and correct any misalignment.
CLUTCH WILL NOT
DISENGAGE PROPERLY
1. Low clutch fluid level.
2. Clutch cover loose.
3. Wrong clutch disc.
4. Disc bent, distorted during
installation.
5. Clutch cover diaphragm spring
bent or warped during
transmission installation.
6. Clutch disc installed backwards.
7. Release fork bent or fork pivot
is loose or damaged.
8. Clutch master or slave cylinder
fault.
1. Top off reservoir and check for
leaks.
2. Tighten bolts.
3. Install correct disc.
4. Replace disc.
5. Replace cover.
6. Remove and reinstall disc correctly.
Be sure disc side marked "to flywheel" is
actually toward flywheel.
7. Replace fork and pivot if worn or
damaged.
8. Replace master and slave cylinder as
assembly.
J9506-1