Chrysler Dodge Caravan 2002 Manual page 239

6 - 4 CLUTCH
CLUTCH (Continued)
CONDITION
CONDITION
DISC FACING WORN OUT
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE
CLUTCH IS RUNNING
PARTIALLY DISENGAGED
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
POSSIBLE CAUSES
Clutch disc damaged or distorted.
Clutch misalignment.
Improper transaxle-to-engine
installation.
SERVICE DIAGNOSIS - CLUTCH SLIPS
POSSIBLE CAUSES
Normal wear.
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.
Insufficient clutch cover diaphragm
spring tension
Leak at rear main oil seal or
transaxle input shaft seal
Excessive amount of grease applied
to input shaft splines
Road splash, water entering housing
Release bearing sticking or binding,
does not return to normal running
position.
Clutch pedal not returning to static
position.
Clutch master cylinder or pushrod
damaged causing high preload.
Slave cylinder binding or stuck.
Leak at rear main or transaxle input
shaft seal
Excessive heat from slippage
CORRECTION
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Verify modular clutch pilot plate alignment
to crankshaft. Replace the modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD) if the pilot plate is loose or
bent.
Verify transaxle is properly installed to
engine.
CORRECTION
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Replace leaking seals. Replace modular
clutch assembly (2.4L Gas) or clutch cover
and disc (2.5L TD).
Apply less grease to input shaft. Replace
modular clutch assembly (2.4L Gas) or
clutch cover and disc (2.5L TD).
Seal housing. Inspect clutch assembly.
Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.
Inspect pedal assembly for damage and/or
obstructions. Replace componnents as
necessary.
Replace clutch master cylinder assembly.
Replace slave cylinder.
Replace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD)..
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
RS