Dodge dakota 2002 Service Manual page 277

6 - 4 CLUTCH
CLUTCH (Continued)
CONDITION
Flywheel below minimum thickness
specification.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
Facing on flywheel side of disc torn,
gouged, or worn.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
Clutch disc binds on input shaft
splines.
Clutch disc rusted to flywheel and/or
pressure plate.
Pilot bearing seized, loose, or rollers
are worn.
POSSIBLE CAUSES
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Rough handling. Impact bent
cover, spring, or disc.
2. Improper bolt tightening
procedure.
1. Flywheel surface scored or
nicked.
2. Clutch disc sticking or binding on
transmission input shaft.
1. Frequent operation under high
loads or hard acceleration
conditions.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
1. Clutch disc hub splines damaged
during installation.
2. Input shaft splines rough,
damaged, or corroded.
1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).
1. Bearing cocked during
installation.
2. Bearing defective.
3. Bearing not lubricated.
4. Clutch misalignment.
CORRECTION
1. Replace flywheel.
1. Replace disc or cover as
necessary.
2. Tighten clutch cover using proper
procedure.
1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Inspect components and
correct/replace as necessary.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
1. Install a new bearing.
2. Install a new bearing.
3. Install a new bearing.
4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
DR