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6 - 2
CLUTCH
•
ments. A p p l y recommended amounts only a n d do not
overlubricate. Refer t o t h e C l u t c h Service section for
specific i n f o r m a t i o n .
S E R V I C E DIAGNOSIS
INDEX
Page
Clutch Problem Causes
. . . . . . . . . . . .
. . . . . 2
General Diagnosis Information
2
GENERAL DIAGNOSIS INFORMATION
Unless t h e cause o f a clutch problem i s extremely
obvious, a road test followed by component inspection
w i l l be r e q u i r e d for accurate diagnosis. The test w i l l
help determine the type of f a u l t a n d component i n -
spection w i l l identify t h e problem component.
D u r i n g a road test, drive t h e vehicle a t n o r m a l
speeds. S h i f t t h e transmission t h r o u g h a l l gear
ranges a n d observe c l u t c h action. I f chatter, grab,
slip, or improper release is experienced, remove and
inspect t h e clutch components. However, i f the prob-
l e m i s noise or h a r d s h i f t i n g , f u r t h e r diagnosis may
be needed as the transmission o r another driveline
component m a y be a t f a u l t . Careful observation dur-
i n g the test w i l l help n a r r o w t h e problem area.
CLUTCH PROBLEM CAUSES
CONTAMINATION
F l u i d contamination i s one o f t h e more common
causes o f c l u t c h malfunctions. O i l , water, or clutch
fluid
on t h e clutch contact surfaces w i l l result i n
f a u l t y operation. The u s u a l r e s u l t i s chatter, slip, or
grab.
D u r i n g inspection, note i f any components are con-
t a m i n a t e d w i t h oil, h y d r a u l i c
fluid,
or water/road
splash.
O i l contamination indicates a leak a t either t h e
rear m a i n seal or transmission i n p u t shaft. O i l leak-
age produces a residue o f o i l on t h e housing i n t e r i o r
and o n t h e clutch cover and flywheel. Heat b u i l d u p
caused b y slippage between t h e cover, disc and fly-
wheel, can sometimes bake t h e o i l residue onto the
components. The glaze-like residue ranges i n color
from amber t o black.
Road splash contamination means dirt/water i s en-
t e r i n g the clutch housing due t o loose bolts, .housing
cracks, or t h r o u g h h y d r a u l i c cylinder openings. D r i v -
i n g t h r o u g h deep water puddles can force water/road
splash i n t o the housing t h r o u g h such openings.
C l u t c h
fluid
leaks are from a loose or damaged
slave cylinder line or connection. However, clutch
fluid leaks w i l l usually be noted a n d corrected before
severe contamination occurs.
Page
Inspection And Diagnosis Charts
5
CLUTCH
MISALIGNMENT
C l u t c h components m u s t be i n proper a l i g n m e n t
w i t h t h e crankshaft a n d t r a n s m i s s i o n i n p u t shaft.
M i s a l i g n m e n t caused b y excessive r u n o u t or warpage
of any c l u t c h component w i l l cause grab, chatter and
improper c l u t c h release.
Flywheel Runout
Common causes o f r u n o u t a r e heat warpage, i m -
proper m a c h i n i n g , m o u n t i n g t h e flywheel o n a d i r t y
crankshaft
flange,
incorrect b o l t t i g h t e n i n g , or i m -
proper seating on t h e crankshaft flange shoulder.
V e r y l i g h t scratches o r surface roughness o n t h e
flywheel
face can be cleaned u p by scuff sanding w i t h
180 g r i t paper. However, i f t h e surface is warped or
severely scored, replace t h e flywheel. D o n o t m a -
c h i n e t h e
flywheel.
T h e
flywheel
face i s m a n u -
f a c t u r e d w i t h a u n i q u e s u r f a c e finish. M a c h i n i n g
w o u l d n e g a t e t h i s f e a t u r e a n d c o u l d r e s u l t i n u n -
s a t i s f a c t o r y o p e r a t i o n .
Clean t h e crankshaft flange before m o u n t i n g t h e
flywheel.
D i r t and grease o n t h e flange surface may
cock t h e flywheel causing r u n o u t . Use n e w bolts
w h e n r e m o u n t i n g a
flywheel
a n d secure t h e bolts
w i t h Mopar Lock A n d Seal. T i g h t e n flywheel bolts to
specified torque only. O v e r t i g h t e n i n g could distort
the flywheel h u b causing r u n o u t .
Clutch Cover And Disc Runout
Check t h e c l u t c h disc before i n s t a l l a t i o n . A x i a l
(face) r u n o u t o f a n e w disc should not exceed .5 m m
(.020 inch). Measure r u n o u t about .35 m m (1/4 inch)
from t h e outer edge o f t h e disc facing. O b t a i n an-
other disc i f r u n o u t i s excessive.
Check condition o f t h e c l u t c h before i n s t a l l a t i o n . A
warped cover or d i a p h r a g m s p r i n g w i l l cause grab
and incomplete release or engagement. Be careful
when h a n d l i n g t h e cover a n d disc. Impact can distort
the cover, d i a p h r a g m s p r i n g , release fingers a n d the
h u b of t h e clutch disc.
Use a n a l i g n m e n t tool w h e n positioning the disc on
the flywheel. T h e tool prevents accidental m i s a l i g n -
ment w h i c h could r e s u l t i n cover distortion a n d disc
damage.
A frequent cause o f c l u t c h cover distortion (and
consequent m i s a l i g n m e n t ) is improper bolt t i g h t e n -
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