Dodge dakota 2002 Service Manual page 276

DR
CLUTCH (Continued)
CLUTCH COVER AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of a new disc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain
another disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator.
Common causes of runout are:
• heat warpage
• improper machining
• incorrect bolt tightening
• improper seating on crankshaft flange shoulder
CONDITION
Disc facing worn out
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
Clutch is running partially
disengaged.
• foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with turning equipment. Remove only
enough material to reduce scoring (approximately
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
warpage after installation; it can also weaken the fly-
wheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction.
Fault conditions are listed at the top of each chart.
Conditions, causes and corrective action are outlined
in the indicated columns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
DIAGNOSIS CHART
POSSIBLE CAUSES
1. Normal wear.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
3. Insufficient clutch cover
diaphragm spring tension.
1. Leak at rear main engine seal or
transmission input shaft seal.
2. Excessive amount of grease
applied to the input shaft splines.
3. Road splash, water entering
housing.
4. Slave cylinder leaking.
1. Release bearing sticking or
binding and does not return to the
normal running position.
CLUTCH
CORRECTION
1. Replace cover and disc.
2. Replace cover and disc.
3. Replace cover and disc.
1. Replace appropriate seal.
2. Remove grease and apply the
correct amount of grease.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Replace hydraulic clutch linkage.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
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