modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.

Fig. 1 Modular Clutch Assembly—2.4L Gas Engines

1 - MODULAR CLUTCH ASSEMBLY

CLUTCH

6a - 1

Models equipped with the 2.5L Turbo Diesel engine

utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it is highly
recommended that the clutch cover and disc be
replaced as a set.

Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines

1 - FLYWHEEL
2 - DISC

3 - PRESSURE PLATE

6a - 2

CLUTCH

CLUTCH (Continued)

RELEASE SYSTEM

All models utilize a hydraulic clutch release sys-

tem, conisting of a clutch master cylinder attached to
the clutch pedal (Fig. 3), and a slave cylinder fas-
tened to the transaxle which operates the clutch
release lever (Fig. 4). When the driver depresses the
clutch pedal, the master cylinder pushrod travels
through the cylinder bore, displacing fluid through
the master cylinder plumbing. This fluid displace-
ment forces the slave cylinder piston to travel, forc-
ing the clutch release bearing into the clutch
diaphragm spring via the release lever and leverage
(Fig. 5). This releases the clamping force on the
clutch disc, allowing the engine crankshaft to rotate
independently from the transaxle input shaft.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CLUTCH SYSTEM

Clutch problem diagnosis will generally require a

road test to determine the type of fault. Component
inspection will then determine the problem after road
testing.

Drive the vehicle at normal speeds during road

test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect

the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.

Fig. 3 Clutch Master Cylinder - Typical

1 - CLUTCH PEDAL
2 - BUSHING
3 - GROMMET
4 - MASTER CYLINDER
5 - STOP

Fig. 4 Slave Cylinder Removal/Installation

1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB

Fig. 5 Release Bearing and Lever

1 - RELEASE LEVER
2 - RELEASE BEARING

CLUTCH

6a - 3

CLUTCH (Continued)

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