Dodge ram truck 3500 1996 Service Manual page 276

6 - 14 CLUTCH
B R
SERVICE PROCEDURES {Continued)
CYLINDER
RESERVOIR
LOCATING
PIN
CLUTCH
& PUSH
. ^ - ^ ROD
CLUTCH
MASTER
CYLINDER
SLAVE
CYLINDER
J9506-25
Fig. 19 Clutch Hydraulic Linkage
PIN
CLIP
PEDAL
J9406-21
Fig. 20 Clutch Cylinder Push Rod Attachment
(17) Remove clutch cylinders, reservoir and con­
necting lines from vehicle.
LINKAGE INSTALLATION
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser­
voir in vehicle engine compartment.
(3) Lubricate cylinder seal with liquid dish soap to
ease installation. Then seat seal in dash and around
cylinder.
(4) Insert clutch master cylinder in dash panel.
Rotate cylinder 45° clockwise to lock i t in place.
(5) I f cylinder seal is hard to seat, unlock cylinder
and reseat seal i f necessary. Then lock cylinder after­
ward.
(6) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N-m
(40 in. lbs.) torque.
(7) Install reservoir mounting bracket on dash
panel, i f removed.
(8) Install replacement bushing on clutch pedal pin
if necessary.
(9) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
(10) Connect clutch pedal position (interlock)
switch wires.
(11) Install locating clip i n clutch master cylinder
mounting bracket.
(12) Raise vehicle.
(13) Install slave cylinder. Be sure cap at end of
cylinder rod is seated i n release lever. Check this
before installing cylinder attaching nuts.
(14) Install and tighten slave cylinder attaching
nuts to 23 N-m (200 in. lbs.) torque.
(15) Lower vehicle.
(16) I f new linkage has been installed, remove
plastic shipping stop from master cylinder push rod.
Do this after installing slave cylinder and before
operating linkage.