Content .. 675 676 677 678 ..

Chrysler RG Voyager. Manual - part 677

CONDITION

POSSIBLE CAUSES

CORRECTION

CLUTCH DISC FACINGS
HAVE FRACTURED
INTO SMALL PIECES

Leak at rear main or transaxle input
shaft seal

Replace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and disc
(2.5L TD)..

Excessive heat from slippage

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE

CONDITION

POSSIBLE CAUSES

CORRECTION

CLUTCH DISC BINDS
ON INPUT SHAFT
SPLINES

Clutch disc hub splines damaged
during installation

Clean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly, or
clutch disc, and/or input shaft if splines are
severely damaged.

Input shaft splines rough, damaged.

Clean input shaft splines. Then lube.

Corrosion or rust formations on
splines of input shaft and disc

Clean input shaft splines and disc splines,
then lube

CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE

Occurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

CLUTCH WILL NOT
DISENGAGE PROPERLY

Disc bent, distorted during transaxle
installation

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Clutch cover diaphragm spring
damaged during transaxle installation

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Release fork bent, loose, or
damaged

Replace fork if worn or damaged

Air in clutch hydraulic circuit.

Allow system to self-bleed or replace
hydraulic components.

Leak in clutch hydraulic circuit.

Replace worn/damaged/leaking hydraulic
components.

Clutch pedal requires
excessive force (high
release load).

Clutch disc is worn.

Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models).

SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE

CONDITION

POSSIBLE CAUSES

CORRECTION

CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR

Pedal bushings worn out or
inadequate lubrication

Replace or lubricate bushings at clutch pedal
pivot or master cylinder pushrod.

Clutch pedal return spring worn out

Lubricate or replace return spring

CLUTCH PEDAL
SQUEAKS DURING
OPERATION

Clutch release lever pivot stud has
inadequate lubrication

Lubricate or replace clutch release lever

CLUTCH

6 - 5

CLUTCH (Continued)

DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT

Common causes of misalignment are:
• Heat warping

• Mounting drive plate on a dirty crankshaft

flange

• Incorrect bolt tightening

• Improper seating on the crankshaft shoulder

• Loose crankshaft bolts
Clean the crankshaft flange before mounting the

drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.

DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT

Check condition of the clutch cover before installa-

tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.

DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS

For all clutch chatter complaints, perform the fol-

lowing:

(1) Check for loose, misaligned, or broken engine

and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.

(2) If chatter persists, check hydraulic clutch

release system is functioning properly.

(3) Check for loose connections in drivetrain. Cor-

rect any problems and determine if clutch chatter
complaints have been satisfied. If not:

(a) Remove transaxle.
(b) Check to see if the release bearing is sticky

or binding. Replace bearing, if needed.

stud and fork fingers. Replace all worn parts.

(d) Check clutch assembly for contamination

(dirt, oil). Replace clutch assembly, if required.

(e) Check to see if the clutch disc hub splines

are damaged. Replace with new clutch assembly, if
necessary.

(f) Check

input

shaft

splines

for

damage.

Replace, if necessary.

(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm

spring fingers. Replace with new clutch assembly,
if necessary.

SPECIAL TOOLS - T850 TRANSAXLE

CLUTCH RELEASE LEVER AND
BEARING

REMOVAL

(1) Remove transaxle assembly. (Refer to 21 -

TRANSMISSION/TRANSAXLE/MANUAL

REMOVAL)

(2) Remove modular clutch assembly from input

shaft (2.4L Gas models only).

(3) Grasp clutch release lever and bearing (Fig. 6)

with both hands and pull outward using moderate
pressure to release lever from pivot ball.

(4) Separate release bearing from lever.

NOTE: Remove release lever pivot ball(s) ONLY if
replacement is necessary.

Disconnect Tool, 6638A

Remover/Installer, 6891

6 - 6

CLUTCH

CLUTCH (Continued)

(5) Remove

pivot

ball(s)

using

slide

hammer

C-3752 and remover/installer 6891 (Fig. 7).

INSTALLATION

(1) If removed, install new release lever pivot

ball(s) using slide hammer C-3752 and remover/in-
staller 6891 (Fig. 8) (Fig. 9).

Fig. 6 Release Bearing and Lever

1 - RELEASE LEVER
2 - RELEASE BEARING

Fig. 7 Pivot Ball Removal/Installation

1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL

Fig. 8 Pivot Ball Removal/Installation

1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL

Fig. 9 Pivot Ball Position

1 - PIVOT BALL (1)

CLUTCH

6 - 7

CLUTCH RELEASE LEVER AND BEARING (Continued)

(2) Install clutch release bearing to lever. Apply

grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).

(3) Apply grease to pivot ball, and on release lever

at slave cylinder contact point.

(4) Install clutch release bearing/lever assembly

into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A “pop” sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.

MASTER CYLINDER - RHD

REMOVAL

(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin

retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).

(3) Disengage master cylinder grommet from cowl

panel.

(4) Remove battery and tray.
(5) Diesel models: Remove windshield wiper mod-

ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)

(6) Discharge Air Conditioning system. (Refer to 24

- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)

(7) Remove suction/discharge line from evaporator

junction block.

(8) Using tool 6638A, disconnect clutch hydraulic

“quick-connect” fitting (Fig. 12).

(9) Remove clutch master cylinder tubing from

retainers in engine compartment.

(10) Remove clutch master cylinder from dash

panel/clutch pedal bracket by rotating 45° clockwise
and pulling outward towards engine (Fig. 13).

(11) Carefully guide clutch master cylinder and

hydraulic plumbing from engine compartment.

Fig. 10 Release Bearing-to-Lever

1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING

Fig. 11 Release Bearing and Lever

1 - RELEASE LEVER
2 - RELEASE BEARING

Fig. 12 Disconnect Quick-Connect Using Tool 6638A

1 - QUICK CONNECT FITTING
2 - TOOL 6638A

6 - 8

CLUTCH

CLUTCH RELEASE LEVER AND BEARING (Continued)

Content .. 675 676 677 678 ..