WARNING: Exercise care when servicing clutch components. Factory installed clutch discs do not contain
asbestos fibers. Dust and dirt on clutch parts may contain asbestos fibers from aftermarket components.
Breathing excessive concentrations of these fibers can cause serious bodily harm. Wear a respirator during
service and never clean clutch components with compressed air or with a dry brush. Either clean the com-
ponents with water dampened rags or use a vacuum cleaner specifically designed to remove asbestos
fibers and dust. Do not create dust by sanding a clutch discs. Replace the disc if the friction material is
damaged. Dispose of all dust and dirt containing asbestos fibers in sealed bags or containers. This will
minimize exposure to yourself and to others. Follow all recommended safety practices prescribed by the
occupational safety and health administration (OSHA) and the environmental safety agency (EPA), for the
handling and disposal of products containing asbestos. Failure to follow these instructions may result in
personal injury or death

DIAGNOSIS AND TESTING

CLUTCH

Road test and inspect components to determine a clutch problem. Road test the vehicle at normal speeds. Shift the
transmission through all gear ranges and observe clutch action. If clutch chatters, grabs, slips or does not release

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properly, remove and inspect clutch components. If problem is noise or hard shifting, further diagnosis may be
needed to the transmission and driveline component.

CLUTCH CONTAMINATION

Contamination is a frequent cause of clutch malfunctions. Oil, water or clutch fluid on the clutch disc and pressure
plate surfaces will cause chatter, slip and grab. Oil contamination indicates a leak at either the rear main seal or
transmission input shaft. Clutch fluid leaks are usually from damaged slave cylinder push rod seals. Heat buildup
caused by slippage between the pressure plate, disc and flywheel can bake the oil residue onto the components.
The glaze-like residue ranges in color from amber to black.

Road splash contamination is dirt/water entering the clutch housing due to loose bolts, housing cracks. Driving
through deep water puddles can force water/road splash into the housing through such openings.

IMPROPER RELEASE OR CLUTCH ENGAGEMENT

Clutch release or engagement problems can be caused by worn or damage clutch components.

Release problems can cause hard shifting and noise. Look for leaks at clutch cylinders, connecting line and loose
slave cylinder bolts. Also worn/loose release fork, pivot stud, clutch disc, pressure plate or release bearing.

Engagement problems can cause slip, chatter/shudder and noisy operation. The causes may be clutch disc con-
tamination, wear, distortion or flywheel damage.

CLUTCH MISALIGNMENT

Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment
caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch
release.

CLUTCH COVER AND DISC RUNOUT

Check the clutch disc before installation. Axial (face) runout of a new disc should not exceed 0.50 mm (0.020 in.).
Measure runout about 6 mm (1/4 in.) from the outer edge of the disc facing. Obtain another disc if runout is exces-
sive.

Check condition of the clutch before installation. A warped cover or diaphragm spring will cause grab and incom-
plete release or engagement. Be careful when handling the cover and disc. Impact can distort the cover, diaphragm
spring, release fingers and the hub of the clutch disc.

Use an alignment tool when positioning the disc on the flywheel. The tool prevents accidental misalignment which
could result in cover distortion and disc damage.

A frequent cause of clutch cover distortion (and consequent misalignment) is improper bolt tightening.

FLYWHEEL RUNOUT

Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the flywheel face with a dial indicator.

Common causes of runout are:

•

heat warpage

•

improper machining

•

incorrect bolt tightening

•

improper seating on crankshaft flange shoulder

•

foreign material on crankshaft flange

Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machin-
ing will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with turning
equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal
is not recommended. 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 flywheel and
interfere with proper clutch release.

Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the fly-
wheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar Lock

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And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub
causing runout.

DIAGNOSIS CHART

The diagnosis charts Diagnosis Chart describe common clutch problems, causes and correction.

Diagnosis Chart

CONDITION

POSSIBLE CAUSES

CORRECTION

Disc facing worn out

1. Normal wear.

1. Replace cover and disc.

2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.

2. Replace cover and disc.

3. Insufficient clutch cover
diaphragm spring tension.

3. Replace cover and disc.

Clutch disc facing contaminated with
oil, grease, or clutch fluid.

1. Leak at rear main engine seal or
transmission input shaft seal.

1. Replace appropriate seal.

2. Excessive amount of grease
applied to the input shaft splines.

2. Remove grease and apply the
correct amount of grease.

3. Road splash, water entering
housing.

3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.

4. Slave cylinder leaking.

4. Replace hydraulic clutch linkage.

Clutch is running partially
disengaged.

1. Release bearing sticking or
binding and does not return to the
normal running position.

1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.

Flywheel below minimum thickness
specification.

1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.

1. Replace flywheel.

Clutch disc, cover and/or diaphragm
spring warped or distorted.

1. Rough handling. Impact bent
cover, spring, or disc.

1. Replace disc or cover as
necessary.

2. Improper bolt tightening
procedure.

2. Tighten clutch cover using proper
procedure.

Facing on flywheel side of disc torn,
gouged, or worn.

1. Flywheel surface scored or
nicked.

1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.

2. Clutch disc sticking or binding on
transmission input shaft.

2. Inspect components and
correct/replace as necessary.

Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.

1. Frequent operation under high
loads or hard acceleration
conditions.

1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.

2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.

2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.

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