Flywheel Service; Removal And Installation; Clutch Cover And Disc - Dodge ram truck 3500 1996 Service Manual

CLUTCH 6 - 1 5
S E R V I C E P R O C E D U R E S ( C o n t i n u e d !
(17) Operate linkage several times to verify proper
operation.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
Minor scratches, burrs, or glazing on the flywheel
face can be scuff sanded with 180 grit emery cloth.
However, the flywheel should be replaced i f 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 rec­
ommended. Replace the flywheel If scoring Is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warping after Installation; It can also weaken the fly­
wheel and Interfere with proper clutch release.
Check flywheel runout i f 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. Mount the dial indi­
cator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel i f the hub exhibits cracks
In the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N ' Seal, or Loctite
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N-m (55 ft. lbs.) for gas engine flywheels
• 137 N-m (101 ft. lbs.) for diesel flywheels
inspect the teeth on the starter ring gear, i f the
teeth are w o r n or damaged, the flywheel should
be replaced as an assembly. This is the recom­
mended and preferred method of repair.
In 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 to
avoid damaging the flywheel and replacement gear.
(1) Mark position of the old gear for alignment ref­
erence on the flywheel. Use a scriber for this pur­
pose.
(2) Wear protective goggles or approved safety
glasses. Also wear heat resistant gloves when han­
dling a heated ring gear.
' (3) Remove the old gear by cutting most of the way
through i t (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or
punch.
(4) The ring gear Is a shrink fit on the flywheel.
This means the gear must be expanded by heating in
order to install It. The method of heating and
expanding the gear is extremely i m p o r t a n t .
Every surface of the gear must be heated at the same
time to produce uniform expansion. An oven or simi­
lar enclosed heating device must be used. Tempera­
ture required for uniform expansion is 325-350° F.
CAUTION: Never use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame will
cause localized heating and damage the flywheel. In
addition, using the torch to heat a replacement gear
will cause uneven heating and expansion. The torch
flame will also anneal the gear teeth resulting in
rapid wear and damage after installation.
(5) The heated gear must be installed evenly to
avoid misalignment or distortion. A shop press and
suitable press plates should be used to install the
gear i f at all possible.
(6) Be sure to wear eye and hand protection. Heat
resistent gloves and safety goggles are needed for
personal safety. Also use metal tongs, vise grips, or
similar tools to position the gear as necessary for
installation.
(7) Allow the flywheel and ring gear to cool down
before installation. Set the assembly on a workbench
and let i t cool i n normal shop air.
CAUTION: Never use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
R E M O V A L A N D I N S T A L L A T I O N
CLUTCH COVER AND DISC
REMOVAL
(1) Raise vehicle.
(2) Remove transmission and transfer case i f
equipped. Refer to Group 21 for procedures.
(3) On models with NV4500 transmission, remove
clutch slave cylinder from clutch housing (Fig. 21).
Then remove transmission and clutch housing from
engine (Fig. 22).
(4) Support engine with wood block and adjustable
jack stand (Fig. 23). Supporting engine is necessary
to avoid undue strain on engine mounts.
(5) I f clutch cover will be reused, mark position of
cover on flywheel with paint or scriber (Fig. 24).