Chrysler RAM TRUCK 2500 1994 Service Manual page 250

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CLUTCH 6 - 17
(9) Remove retaining clip, flat washer and wave
washer that attach clutch master cylinder push rod
to clutch pedal (Fig. 18).
(10) Slide clutch master cylinder push rod off pedal
pin.
(11) Inspect condition of bushing on clutch pedal
pin (Fig. 18). Remove and replace bushing i f worn or
damaged.
(12) Verify that cap on clutch master cylinder res­
ervoir is tight. This will avoid spillage during re­
moval.
(13) Remove screws that attach clutch fluid reser­
voir to dash panel.
(14) Remove reservoir mounting bracket screws
and remove reservoir from dash panel.
(15) Rotate clutch master cylinder 45° counter­
clockwise to unlock it. Then remove cylinder from
dash panel.
(16) Remove clutch master cylinder rubber seal
from dash panel (Fig. 17).
(17) Remove clutch cylinders, reservoir and con­
necting lines from vehicle.
PIN
PEDAL
J9406-21
Fig. 18 Clutch Cylinder Push Rod Attachment
LINKAGE INSTALLATION
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser­
voir i n vehicle engine compartment.
(3) Lubricate cylinder seal with liquid dish soap to
ease installation. Then seat seal i n dash and around
cylinder.
(4) Insert clutch master cylinder i n dash panel. Ro­
tate cylinder 45° clockwise to lock i t i n place.
(5) I f cylinder seal is hard to seat, unlock cylinder
and reseat seal i f necessary. Then relock cylinder af­
terward.
(6) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N-m
(40 in. lbs.) torque.
(7) Install reservoir mounting bracket on dash
panel, i f removed.
(8) Install replacement bushing on clutch pedal pin
if necessary.
(9) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
(10) Connect clutch pedal position (interlock)
switch wires.
(11) Install locating clip i n clutch master cylinder
mounting bracket.
(12) Raise vehicle.
(13) Install slave cylinder. Be sure cap at end of
cylinder rod is seated i n release lever. Check this be­
fore installing cylinder attaching nuts.
(14) Install and tighten slave cylinder attaching
nuts to 23 N-m (200 in. lbs.) torque.
(15) Lower vehicle.
(16) I f new linkage has been installed, remove
plastic shipping stop from master cylinder push rod.
Do this after installing slave cylinder and before op­
erating linkage.
(17) Operate linkage several times to verify proper
operation.
CLUTCH PEDAL REMOVAL
(1) Remove retaining ring, flat washer and wave
washer that secure brake and clutch pedals to push
rods (Fig. 18).
(2) Remove knee bolster (Fig. 19) for access to
pedal pivot shaft.
Fig. 19 Knee Bolster Removal
(3) Remove brakelight switch. Turn switch clock­
wise about 30° to release i t then remove switch from
bracket.