Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual - part 300

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) 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.

DIAGNOSIS AND TESTING - CLASH-INTO-
REVERSE COMPLAINTS

All T350 manual transaxles are equipped with a

reverse brake. It prevents clash when shifting into
reverse, but only if the vehicle is not moving.

(1) Depress clutch pedal to floor and hold. After

three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.

(2) Remove transaxle.
(3) Check the input shaft spline, clutch disc

splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.

(4) Check to see if the clutch disc hub splines are

damaged, and replace with new clutch assembly if
required.

(5) Check the input shaft for damaged splines.

Replace as necessary.

(6) Check

for

broken

clutch

cover

diaphragm

spring fingers.

(7) Install clutch assembly and transaxle.

SPECIFICATIONS

CLUTCH

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Clutch Pedal Pivot Shaft

Nut

—

Modular Clutch-to-Drive

Plate

—

Transaxle-to-Engine

Mounting Bolts

—

CLUTCH

6 - 5

CLUTCH (Continued)

SPECIAL TOOLS

CLUTCH PEDAL

REMOVAL

(1) Remove instrument panel left lower sound

insulator.

(2) Using suitable pliers, remove clutch pedal

return spring (Fig. 5).

(3) Remove clutch upstop spacer retainer clip from

pedal pin (Fig. 5). Remove cable/spacer from pedal.

(4) Remove clutch pedal pivot shaft and nut.
(5) Remove clutch pedal assembly (Fig. 6). Inspect

bushings for excessive wear and replace as necessary.

INSTALLATION

(1) Install clutch pedal assembly into position.
(2) Install pivot shaft and nut as shown in (Fig. 6)

and torque to 31 N·m (23 ft. lbs.) torque.

(3) Install clutch cable/upstop spacer to clutch

pedal pin (Fig. 5). An audible “click” should be heard.
Verify upstop spacer retainer is intact and secures
spacer.

(4) Install clutch pedal return spring (Fig. 5).

Install to pedal blade first, then slip into position at
pedal bracket using suitable pliers.

(5) Verify proper clutch pedal operation, as well as

proper interlock switch contact.

(6) Install instrument panel left lower sound insu-

lator.

Puller, C-3752

Remover/Installer, 6891

Fig. 5 Clutch Pedal Upstop Spacer and Return

Spring

1 - UPSTOP SPACER
2 - RETURN SPRING
3 - CLUTCH PEDAL
4 - CLUTCH CABLE

Fig. 6 Clutch Pedal Removal/Installation

1 - SHAFT
2 - BRACKET
3 - NUT
4 - BUSHING (2)
5 - PEDAL

6 - 6

CLUTCH

CLUTCH (Continued)

CLUTCH PEDAL INTERLOCK
SWITCH

DIAGNOSIS AND TESTING - CLUTCH PEDAL
INTERLOCK SWITCH

CLUTCH PEDAL INTERLOCK SWITCH–ELECTRICAL
TEST

Disconnect clutch pedal interlock switch harness

from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
the switch is in its normal (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050), the ohmmeter should show continuity (zero
ohms).

If ohmmeter readings do not fall within these

ranges, the switch is defective, and must be replaced.

CLUTCH PEDAL INTERLOCK
SWITCH–MECHANICAL TEST

With the park brake set and the vehicle IN NEU-

TRAL, turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is

defective (shorted out) and must be replaced. If the
vehicle does not crank proceed to the next step.

WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.

With the park brake set, the brake pedal fully

depressed, and the vehicle IN GEAR, turn the key to
the start position and hold it there.

Slowly depress the clutch pedal and feel for any

vehicle motion when the starter is energized. If there
is no motion the switch is working properly.

If motion is felt, check to see if the switch is mak-

ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch or
the self-adjusting cable (See “Clutch Will Not Disen-
gage Properly”). If this condition is not met, then the
switch mounting tab on the brake bracket is bent,
and the brake bracket must be replaced.

If vehicle will not crank, even with clutch pedal

pressed to the floor, refer to “Service Diagnosis-
Clutch Pedal Position Switch” chart in this section.

SERVICE DIAGNOSIS–CLUTCH PEDAL POSITION SWITCH

CONDITION

POSSIBLE CAUSE

CORRECTION

ENGINE WON’T CRANK WHEN
CLUTCH PEDAL IS DEPRESSED
TO THE FLOOR

Switch does not have continuity
when plunger is depressed 1.25
mm

Defective switch. Replace switch.

Switch plunger is not depressed
when clutch pedal is depressed to
the floor.

Floor mat or other obstruction
interferes with clutch pedal
movement.

Problem is related to other
components in the starting circuit.

Check other components in the
starting circuit. Refer to Section 8A.

CLUTCH

6 - 7

REMOVAL

(1) Disconnect battery negative cable.
(2) Remove steering column lower panel.
(3) Remove knee bolster.
(4) Disconnect position switch connector.
(5) Depress wing tabs on switch and push switch

out of mounting bracket (Fig. 7).

INSTALLATION

(1) Slide switch wires through slot in bracket.
(2) Line up switch tab with slot in bracket and

push switch into position (Fig. 7).

(3) Attach switch connector.
(4) Install knee bolster.
(5) Install steering column lower panel.
(6) Connect battery negative cable.

CLUTCH RELEASE BEARING
AND LEVER

DESCRIPTION

A conventional release bearing is used to engage

and disengage the clutch pressure plate. The clutch
release bearing is mounted on the transaxle front
bearing retainer. The bearing is attached to and oper-
ated by the release lever (Fig. 8), which moves the
bearing into contact with the clutch cover diaphragm
spring.

OPERATION

The release bearing is operated by the release

lever (Fig. 8). Pressure applied to the clutch pedal
transmits force through the clutch cable, causing the
release lever to move the release bearing into contact
with the diaphragm spring. As additional force is
applied, the bearing presses the diaphragm spring
fingers inward on the fulcrums. This action moves
the pressure plate rearward, relieving clamping force
on the clutch disc. Releasing pedal pressure reduces
the force applied to the release lever. The release
bearing then moves away from the diaphragm spring
which allows the pressure plate to exert clamping
force on the clutch disc.

Fig. 7 Clutch Pedal Interlock Switch

1 - CLUTCH CABLE
2 - UPSTOP SPACER
3 - CLUTCH PEDAL INTERLOCK SWITCH
4 - CLUTCH PEDAL
5 - CLUTCH PEDAL RETURN SPRING

Fig. 8 Clutch Release Lever and Bearing

1 - LEVER
2 - BEARING

6 - 8

CLUTCH

CLUTCH PEDAL INTERLOCK SWITCH (Continued)

Content .. 298 299 300 301 ..