Chrysler RAM TRUCK 2500 1994 Service Manual page 251

6 - 18 CLUTCH
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(4) Remove retainer from passenger side of pedal
pivot shaft (Fig. 20).
PEDAL PEDAL
SUPPORT PIVOT
19406-22
Fig. 20 Clutch/Brake Pedal Mounting
(5) Push pedal pivot shaft toward driver side of
support only enough to remove clutch pedal. It is not
necessary to remove shaft from pedal support en­
tirely.
(6) Remove clutch pedal.
CLUTCH PEDAL INSTALLATION
(1) Inspect bushings in clutch and brake pedals
(Fig. 21). Replace bushings if worn, cracked, or dis­
torted.
Fig. 21 Clutch/Brake Pedal Bushings
(2) Lubricate pedal shaft, pedal shaft bore (Figs.
20 and 21) and all bushings with Mopar Multi Mile­
age, or high temperature bearing grease.
(3) Position clutch pedal in support. Align pedal
with pivot shaft and slide shaft through pedal bush­
ings. Then repeat process for brake pedal.
(4) Slide pedal shaft through support and install
shaft retainer.
(5) Secure push rods to clutch and brake pedals.
(6) Install brakelight switch in bracket. Rotate
switch into place to lock it in bracket.
(7) Install knee bolster.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
Minor scratches, burrs, or glazing on the flywheel
face can be scuff sanded with 180 grit emery cloth.
However, the flywheel should be replaced if the disc
contact surface is severely scored, heat checked,
cracked, or obviously worn.
Cleanup of minor flywheel scoring should be per­
formed with surface grinding equipment. Remove
only enough material to reduce scoring (approximate­
ly 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.
Check flywheel runout if misalignment is sus­
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the fly­
wheel face with a dial indicator. Mount the dial indi­
cator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N' Seal, or Loctite
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N-m (55 ft. lbs.) for gas engine flywheels
• 137 N-m (101 ft. lbs.) for diesel flywheels
Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom­
mended and preferred method of repair.
In cases where a new flywheel is not readily avail­
able, a replacement ring gear can be installed. How­
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.