Dodge Viper SRT-10 (ZB). Manual - part 46

CLUTCH DISC

Clutch disc runout should not exceed 0.5 mm

(0.020 in.). Check runout 6 mm (0.25 in.) from the
outer edge of the disc. Replace clutch disc if the worn
within 0.38 mm (0.015 in.) of the rivet heads. Inspect
clutch disc for:

• Discoloration

• Burned Areas

• Cracks

• Worn Disc Hub Splines

• Broken Springs

• Lose Rivets

• Oil Soaked

DIAGNOSIS CHART

The diagnosis charts Diagnosis Chart describe

common clutch problems, possible causes and correc-
tion.

DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSES

CORRECTION

Disc facing worn out

1. Normal wear.

1. Replace pressure plate and disc.

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

2. Replace pressure plate and disc.

3. Insufficient pressure plate
diaphragm spring tension.

3. Replace pressure plate 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
pressure plate 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.

Pressure plate or diaphragm spring
warped or distorted.

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

1. Replace disc and pressure plate
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.

6 - 4

CLUTCH

CLUTCH (Continued)

CONDITION

POSSIBLE CAUSES

CORRECTION

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

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

1. Correct condition of flywheel and
pressure plate surface. Replace disc
and pressure plate.

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.

Clutch disc binds on input shaft
splines.

1. Clutch disc hub splines damaged
during installation.

1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.

2. Input shaft splines rough,
damaged, or corroded.

2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.

Clutch disc rusted to flywheel and/or
pressure plate.

1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).

1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.

Pilot bearing seized, loose, or rollers
are worn.

1. Bearing cocked during
installation.

1. Install and lubricate a new
bearing.

2. Bearing defective.

2. Install and lubricate a new
bearing.

3. Bearing not lubricated.

3. Install and lubricate a new
bearing.

4. Clutch misalignment.

4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.

Clutch will not disengage properly.

1. Low clutch fluid level.

1. Replace hydraulic linkage
assembly.

2. Clutch cover loose.

2. Follow proper bolt tightening
procedure.

3. Clutch disc bent or distorted.

3. Replace clutch disc.

4. Pressure plate diaphragm spring
bent or warped.

4. Replace pressure plate.

5. Clutch disc installed backwards.

5. Remove and install clutch disc
correctly.

6. Release fork bent or fork pivot
loose or damaged.

6. Replace fork or pivot as
necessary.

7. Clutch master or slave cylinder
failure.

7. Replace hydraulic linkage
assembly.

Clutch pedal squeak.

1. Pivot pin loose.

1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.

2. Master cylinder bushing not
lubricated.

2. Lubricate master cylinder
bushing.

3. Pedal bushings worn out or
cracked.

3. Replace and lubricate bushings.

CLUTCH

6 - 5

CLUTCH (Continued)

CONDITION

POSSIBLE CAUSES

CORRECTION

Clutch master or slave cylinder
plunger dragging andør binding

1. Master or slave cylinder
components worn or corroded.

1. Replace clutch hydraulic linkage
assembly.

Release bearing is noisy.

1. Release bearing defective or
damaged.

1. Replace release bearing.

Contact surface of release bearing
damaged.

1. Pressure plate release fingers
bent or distorted.

1. Replace pressure plate and
release bearing.

2. Release bearing defective or
damaged.

2. Replace the release bearing.

3. Release bearing misaligned.

3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.

Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.

1. Clutch pressure plate position
incorrect.

1. Replace clutch disc and pressure
plate.

2. Pressure plate release fingers
bent or distorted.

2. Replace clutch disc and pressure
plate.

3. Clutch disc damaged or
distorted.

3. Replace clutch disc.

4. Clutch misalignment.

4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.

STANDARD PROCEDURE - CLUTCH SYSTEM
BLEED

To determine if the master cylinder assembly

requires bleeding or if the complete system requires
bleeding:

(1) Uncouple the clutch master cylinder line from

the clutch slave cylinder with quick Disconnect Tool
6638.

(2) Slowly depress the clutch pedal.

CAUTION: Do not apply too much force as this will
cause the uncoupled male coupling to blow out.

(3) If the pedal feels hard in a relatively short dis-

tance, air is present in the clutch slave cylinder.

(4) If the pedal feels spongy air is present in the

master cylinder assembly.

LINKAGE BLEED

(1) Remove the reservoir cap taking care not to

damage the diaphragm (Fig. 5). If fluid level is not
up to the step in the reservoir add D.O.T. 4 brake
fluid.

CAUTION: Use only D.O.T. 4 compatible brake fluid.
Other than D.O.T 4 will cause system malfunction.

Fig. 5 HYDRAULIC CLUTCH RESERVOIR

1 - HYDRAULIC CLUTCH RESERVOIR
2 - POWER BRAKE BOOSTER
3 - BRAKE MASTER CYLINDER
4 - CLUTCH MASTER CYLINDER
5 - HYDRAULIC CLUTCH LINE

6 - 6

CLUTCH

CLUTCH (Continued)

(2) Slowly depressing the clutch pedal while open-

ing the clutch slave cylinder bleed screw (Fig. 6).

(3) Holding down the clutch pedal and tighten

bleed screw to 15-20 N·m (11-14 ft. lbs.).

(4) Repeat Step 2 and Step 3 two times then check

fluid level in reservoir.

(5) Pump clutch pedal rapidly a minimum of 10

times. If clutch pedal still feels spongy, repeat Step 2
through Step 5.

MASTER CYLINDER BLEED

(1) Uncouple the master cylinder line from the

clutch slave cylinder, with quick Disconnect Tool
6638.

(2) Remove the reservoir cap taking care not to

damage the diaphragm. If the fluid level is not up to
the step in the reservoir, add D.O.T. 4 brake fluid.

CAUTION: Use only D.O.T. 4 compatible brake fluid.
Other than D.O.T 4 will cause system malfunction.

(3) Open the male quick connect coupling by

depressing the poppet in the coupling while depress
the clutch pedal to the floor.

(4) Close the quick connect coupling by releasing

the poppet while holding the clutch pedal to the floor.

(5) Release the pedal.
(6) Repeat Step 3 through Step 5 two more times

and check fluid level.

(7) Couple system back together. Then pump

clutch pedal rapidly a minimum of 10 times.

(8) If clutch pedal still feels spongy repeat Step 3

through Step 7.

SPECIFICATIONS

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Clutch Bleed Screw

156

Clutch Cover Bolts

270

Clutch Release Bearing

200

Flywheel Bolts

SPECIAL TOOLS

Fig. 6 RELEASE BEARING/HYDRAULIC SLAVE

CYLINDER

1 - HYDRAULIC CLUTCH RELEASE
2 - BLEED SCREW
3 - TRANSMISSION

HYDRAULIC LINE DISCONNECT 6638

CLUTCH

6 - 7

CLUTCH (Continued)

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