Chrysler 1998 Voyager Service Manual page 205

NS/GS
DIAGNOSIS AND TESTING (Continued)
CONDITION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINES
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE
CLUTCH WILL NOT
DISENGAGE PROPERLY
CONDITION
CLUTCH PEDAL MAKES
REPEATED POP NOISE
IN THE FIRST INCH OF
TRAVEL
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR
DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
• Heat warping
• Mounting drive plate on a dirty crankshaft
flange
• Incorrect bolt tightening
• Improper seating on the crankshaft shoulder
• Loose crankshaft bolts
SERVICE DIAGNOSIS–IMPROPER CLUTCH RELEASE
POSSIBLE CAUSES
Clutch disc hub splines damaged during
installation
Input shaft splines rough, damaged.
Corrosion or rust formations on splines
of input shaft and disc
Occurs in vehicles stored or not driven
for extended period of time. Also occurs
after steam cleaning if vehicle is not
used for extended period.
Disc bent, distorted during transaxle
installation
Clutch cover diaphragm spring damaged
during transaxle installation
Release fork and (or) bushings
damaged
Clutch cable binding or routed
incorrectly
Self-adjuster in cable not functioning
properly, resulting in excess cable slack
Clutch pedal travel restricted
SERVICE DIAGNOSIS–CLUTCH PEDAL NOISE
POSSIBLE CAUSES
Self-adjusting mechanism in cable
defective (LHD Applications)
Pedal bushings worn out or inadequate
lubrication
Clutch pedal assist spring fittings worn
out
Clutch release shaft bushings in the
bellhousing are worn out
Clean, smooth, and lubricate disc and
shaft splines. Replace clutch assembly
and/or input shaft if splines are severely
damaged.
Clean input shaft splines. Then lube.
Clean input shaft splines and disc
splines, then lube
Replace clutch assembly
Replace clutch assembly
Replace clutch assembly
Replace fork and (or) bushings if worn or
damaged
Check and correct cable routing
Pull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
Verify clutch pedal can travel all the way
to the downstop on the bracket
Replace clutch cable (LHD Applications)
Replace or lubricate bushings
Replace assist spring fittings
Replace release shaft and bushings
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
CLUTCH
CORRECTION
CORRECTION
6 - 7