Table of Contents
Advertisement
•
CLUTCH
6 - 13
PILOT BUSHING REPLACEMENT
(1) Remove the transmission and clutch housing.
(2) Remove t h e c l u t c h cover and disc.
(3) Remove the p i l o t b u s h i n g . Use a n i n t e r n a l type
p u l l e r tool o r collapse t h e b u s h i n g w i t h a punch and
remove i t .
(4) Clean t h e b u s h i n g bore w i t h solvent and d r y
w i t h compressed air.
(5) I n s t a l l t h e new b u s h i n g w i t h a n a l i g n m e n t tool
or spare i n p u t shaft. T h e b u s h i n g should be flush
w i t h the edge o f t h e b u s h i n g bore. Do not recess t h e
bushing.
(6) Lubricate t h e b u s h i n g w i t h Mopar H i g h Tem-
perature grease, or equivalent only. Do not use a n y
other type o f l u b r i c a n t o n t h e bushing.
(7) I n s t a l l t h e clutch cover and disc.
(8) I n s t a l l t h e transmission and clutch housing.
CLUTCH LINKAGE SERVICE
T h e c l u t c h m a s t e r c y l i n d e r , r e m o t e
r e s e r v o i r ,
s l a v e c y l i n d e r a n d c o n n e c t i n g l i n e s a r e a l l ser-
v i c e d as a n a s s e m b l y . T h e s e c o m p o n e n t s c a n n o t
b e s e r v i c e d s e p a r a t e l y . T h e c y l i n d e r s a n d c o n -
n e c t i n g l i n e s a r e s e a l e d u n i t s . T h e y a r e p r e f i l l e d
w i t h f l u i d d u r i n g m a n u f a c t u r e a n d m u s t n o t b e
d i s a s s e m b l e d n o r d i s c o n n e c t e d .
LINKAGE
REMOVAL
(1) Raise t h e vehicle.
(2) Remove the n u t s a t t a c h i n g the slave cylinder t o
t h e clutch housing.
(3) Remove t h e slave cylinder a n d clip from t h e
housing.
(4) Lower t h e vehicle.
(5) Carefully remove t h e locating clip from t h e
clutch master cylinder m o u n t i n g bracket (Fig. 6).
(6) Remove t h e r e t a i n i n g r i n g , flat washer a n d
wave washer t h a t attach t h e clutch master cylinder
push rod t o t h e c l u t c h pedal (Fig. 6).
(7) Slide t h e c l u t c h master cylinder push rod off the
clutch pedal p i n .
(8) Inspect condition o f t h e bushing on t h e clutch
pedal p i n . Remove and replace t h e bushing i f w o r n or
damaged.
(9) Verify t h a t the cap o n t h e clutch master c y l i n -
der reservoir i s t i g h t . T h i s is necessary to avoid u n -
due spillage d u r i n g removal.
(10) Remove t h e screws a t t a c h i n g the clutch f l u i d
reservoir t o t h e dash panel.
(11) I f necessary, remove t h e reservoir m o u n t i n g
bracket screws a n d remove the bracket from the dash
panel.
(12) P u l l t h e c l u t c h master cylinder rubber seal
from t h e dash panel (Fig. 6).
(13) Rotate t h e c l u t c h master cylinder 45 degrees
counterclockwise t o unlock i t . T h e n remove t h e cyl-
inder f r o m t h e dash panel.
(14) Remove t h e c l u t c h cylinders, reservoir a n d
connecting lines from the vehicle.
LINKAGE
INSTALLATION
(1) T i g h t e n t h e cap o n the c l u t c h fluid reservoir t o
avoid spillage d u r i n g i n s t a l l a t i o n .
(2) Position t h e cylinders, connecting lines and res-
ervoir i n t h e vehicle.
(3) I n s e r t t h e c l u t c h master cylinder i n t h e dash
panel. Rotate t h e cylinder 45 degrees clockwise t o
lock i t i n place.
(4) L u b r i c a t e t h e master cylinder rubber seal w i t h
l i q u i d d i s h soap t o ease i n s t a l l a t i o n . Then seat t h e
seal i n t h e dash and around the cylinder.
(5) Position t h e reservoir on the dash panel and i n -
s t a l l t h e reservoir screws. T i g h t e n t h e screws to 5
N*m (40 in-lbs) torque.
(6) I n s t a l l t h e reservoir m o u n t i n g bracket on t h e
dash panel, i f removed.
(7) I n s t a l l a replacement b u s h i n g on t h e clutch
pedal p i n i f necessary.
(8) I n s t a l l t h e c l u t c h master cylinder push rod on
the c l u t c h pedal p i n . Secure t h e rod w i t h t h e wave
washer, flat washer and retainer r i n g .
(9) I n s t a l l t h e locating clip i n t h e clutch master
cylinder m o u n t i n g bracket.
(10) Raise t h e vehicle.
(11) I n s e r t t h e slave cylinder push rod t h r o u g h the
clutch h o u s i n g opening and i n t o t h e release lever. Be
sure t h e cap o n t h e end of the r o d is securely en-
gaged i n t h e release lever. Check t h i s before i n s t a l l -
i n g t h e c y l i n d e r a t t a c h i n g nuts.
(12) I n s t a l l and t i g h t e n t h e slave cylinder attach-
i n g n u t s t o 23 N»m (200 in-lbs) torque.
(13) L o w e r t h e vehicle.
(14) I f a n e w linkage has been installed, remove
the plastic s h i p p i n g stop from t h e master cylinder
push rod—-after i n s t a l l i n g t h e slave cylinder—and
before operating t h e linkage.
(15) Operate
t h e linkage a few times to verify
proper operation.
Advertisement
Table of Contents
