Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Driven Disc & Pressure Plate

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Adjustments



These vehicles use a clutch cable with a unique self-adjuster mechanism built into the cable which compensates for clutch disc wear. No bleeding is necessary or possible. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. The cable requires no maintenance or lubrication.

Removal & Installation




NOTE
The transaxle assembly must be removed to service the clutch assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.



    Negative battery cable from the left shock tower
     



    Starter
     
    Rear and front transaxle support brackets
     
    Clutch inspection cover
     
    Modular clutch-to-flywheel bolts
     
    Transaxle assembly with the clutch as an assembly
     
    Clutch assembly from the transaxle input shaft

    Click image to see an enlarged view

    Fig. Exploded view of the clutch assembly

     

  4.  

To install:

  1. Clean all parts well. Inspect for oil leakage through the engine rear crankshaft oil seal and transaxle input shaft seal. If leakage is noted, it should be corrected at this time.
  2.  
  3. Examine the throw out or clutch release bearing. It is pre-lubricated and sealed and should not be washed in solvent. The bearing should turn smoothly when held in the hand with a light thrust load. A light drag caused by the lubricant fill is normal. If the bearing is noisy, rough or dry, replace the complete bearing assembly. In most cases where a clutch is being serviced, the complete clutch assembly and release bearing are usually replaced together.
  4.  
  5. Check the condition of the stud pivot spring clips on the back side of the clutch fork. If the clips are broken or distorted, replace the clutch fork. The pivot ball pocket in the fork is Teflon® coated and should be installed WITHOUT any lubricant such as grease which will break down the Teflon® coating. Be sure the ball stud and fork pocket are clean of contamination and dirt. When assembling the fork to the bearing, the small pegs on the bearing must go over the fork arms.
  6.  
  7. Check the flywheel for cracks, glazing or grooves. If any of these conditions exist, machine (reface) or replace the flywheel to prevent clutch chatter and premature clutch wear.
    NOTE
    The manual transaxle is equipped with a reverse brake. It functions as a synchronizer, but only if the vehicle is not moving. When the clutch pedal is depressed to the floor and held for 3 seconds, and the transaxle shifts to reverse, no gear clash should be present. If there is, the input shaft should be checked. When the transaxle is removed for clutch service, check the input clutch shaft, clutch disc splines and release bearing for dry rust. If present, clean rust off and apply a light coat of high temperature 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 splines.

  8.  
  9. Install or connect the following:

    Modular clutch assembly onto the transaxle input shaft
     
    Transaxle assembly
     
    New clutch-to-driveplate (flywheel) bolts. Tighten the bolts, in a crisscross pattern, a few turns at a time to 55 ft. lbs. (75 Nm)
     
    Clutch inspection cover
     
    Transaxle lower support brackets
     
    Starter
     
    Negative battery cable
     

  10.  
  11. Road test vehicle to check for proper clutch operation.
  12.  


NOTE
The transaxle assembly must be removed to service the clutch assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.



    The negative battery cable from the left shock tower
     



    The starter
     
    The rear and front transaxle support brackets
     
    The clutch inspection cover
     
    The modular clutch-to-flywheel bolts
     
    The transaxle assembly with the clutch as an assembly
     
    The clutch assembly from the transaxle input shaft

    Click image to see an enlarged view

    Fig. Exploded view of the clutch assembly

     

  4.  

To install:

  1. Clean all parts well. Inspect for oil leakage through the engine rear crankshaft oil seal and transaxle input shaft seal. If leakage is noted, it should be corrected at this time.
  2.  
  3. Examine the throw-out or clutch release bearing:

    The throw-out or clutch release bearing is pre-lubricated and sealed and should not be washed in solvent
     
    The bearing should turn smoothly when held in the hand with a light thrust load. A light drag caused by the lubricant fill is normal
     
    If the bearing is noisy, rough or dry, replace the complete bearing assembly
     
    In most cases, where a clutch is being serviced, the complete clutch assembly and release bearing are replaced together
     

  4.  
  5. Check the condition of the stud pivot spring clips on the back side of the clutch fork:

    If the clips are broken or distorted, replace the clutch fork
     
    The pivot ball pocket in the fork is Teflon® coated and should be installed WITHOUT any lubricant such as grease which will break down the Teflon® coating
     
    Be sure the ball stud and fork pocket are clean of contamination and dirt
     
    When assembling the fork to the bearing, the small pegs on the bearing must go over the fork arms
     

  6.  
  7. Check the flywheel for cracks, glazing or grooves. If any of these conditions exist, machine (reface) or replace the flywheel to prevent clutch chatter and premature clutch wear.
    NOTE
    The manual transaxle is equipped with a reverse brake. It functions as a synchronizer, but only if the vehicle is not moving. When the clutch pedal is depressed to the floor and held for 3 seconds, and the transaxle shifts to reverse, no gear clash should be present. If there is, the input shaft should be checked. When the transaxle is removed for clutch service, check the input clutch shaft, clutch disc splines, and the release bearing for dry rust. If present, clean rust off and apply a light coat of high temperature 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 splines.

  8.  
  9. Install or connect the following:

    The modular clutch assembly onto the transaxle input shaft
     
    The transaxle assembly
     
    The new clutch-to-driveplate (flywheel) bolts. Tighten the bolts, in a crisscross pattern, a few turns at a time to 55 ft. lbs. (75 Nm)
     
    The clutch inspection cover
     
    The transaxle lower support brackets
     
    The starter
     
    The negative battery cable
     

  10.  
  11. Road test the vehicle to check for proper clutch operation.
  12.  

2.0L & 2.5L Engines


Click image to see an enlarged view

Fig. Exploded view of the clutch assembly

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If the pressure plate is to be reused, loosen the bolts in a diagonal pattern 1 turn at a time. This will prevent warping the clutch cover assembly.



    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Transaxle
     
    Pressure plate-to-flywheel bolts, pressure plate and clutch disc
     

  4.  
  5. Remove the return clip and the pressure plate release bearing. Do not use solvent to clean the bearing.
  6.  
  7. Inspect the clutch release fork and fulcrum for damage or wear. If necessary, remove the release fork and the fulcrum from the transaxle.
  8.  
  9. Carefully inspect the condition of the clutch components and replace any worn or damaged parts.
  10.  

To install:

  1. Inspect the flywheel for heat damage or cracks. Resurface or replace the flywheel as required.
  2.  
  3. Install or connect the following:
    NOTE
    Apply a coating of multi-purpose grease to the point of contact with the fulcrum and the point of contact with the release bearing. Apply a coating of multi-purpose grease to the end of the release cylinder's pushrod and the pushrod hole in the release fork.


    WARNING
    When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. Excessive grease will cause clutch slippage and shudder.



    Flywheel using new bolts
     
    Fulcrum, if removed, and tighten
     
    Release fork
     

  4.  
  5. Apply multi-purpose grease to the clutch release bearing. Pack the bearing inner surface and the groove with grease. Do not apply grease to the resin portion of the bearing. Place the bearing in position and install the return clip.
  6.  
  7. Apply a coating of grease to the clutch disc splines, then use a brush to rub it in the grooves. Using a clutch disc alignment tool, position the clutch disc on the flywheel. Install the retainer bolts and tighten a little at a time, in a diagonal sequence.
  8.  
  9. Install the transaxle assembly and check the fluid level.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Verify proper clutch operation.
  14.  



Click image to see an enlarged view

Fig. Exploded view of the clutch assembly

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If the pressure plate is to be reused, loosen the bolts in a diagonal pattern, one or 2 turns at a time. This will prevent warping the clutch cover assembly.



    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Transaxle
     
    Pressure plate-to-flywheel bolts, pressure plate and clutch disc
     

  4.  
  5. Remove the return clip and the pressure plate release bearing. Do not use solvent to clean the bearing.
  6.  
  7. Inspect the clutch release fork and fulcrum for damage or wear. If necessary, remove the release fork and the fulcrum from the transaxle.
  8.  
  9. Carefully inspect the condition of the clutch components and replace any worn or damaged parts.
  10.  

To install:

  1. Inspect the flywheel for heat damage or cracks. Resurface or replace the flywheel as required.
  2.  
  3. Install or connect the following:
    NOTE
    Apply a coating of multi-purpose grease to the point of contact with the fulcrum and the point of contact with the release bearing. Apply a coating of multi-purpose grease to the end of the release cylinder's pushrod and the pushrod hole in the release fork.


    WARNING
    When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. Excessive grease will cause clutch slippage and shudder.



    Flywheel using new bolts
     
    Fulcrum, if removed, and tighten
     
    Release fork
     

  4.  
  5. Apply multi-purpose grease to the clutch release bearing. Pack the bearing inner surface and the groove with grease. Do not apply grease to the resin portion of the bearing. Place the bearing in position and install the return clip.
  6.  
  7. Apply a coating of grease to the clutch disc splines, then use a brush to rub it in the grooves. Using a clutch disc alignment tool, position the clutch disc on the flywheel. Install the retainer bolts and tighten a little at a time, in a diagonal sequence.
  8.  
  9. Install the transaxle assembly and check the fluid level.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Verify proper clutch operation.
  14.  

2.4L & 3.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Clutch fluid line bracket
     
    Insulator, washer and clutch tube
     
    Union, union bolt and gasket
     
    Valve and spring, 3.0L engine
     
    Clutch release cylinder
     
    Clutch cover and disc
     
    Release fork shaft, 3.0L engine
     
    Left support spring, 3.0L engine
     
    Release fork
     
    Clutch release bearing
     
    Release fork boot and fulcrum, 2.4L engine
     
    Release fork boot and maintenance cover, 3.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the clutch assembly-3.0L engine shown, 2.4L similar

     

  4.  

To install:

  1. Install or connect the following:

    Release fork boot and maintenance cover, 3.0L engine
     
    Release fork boot and fulcrum and torque the fulcrum to 26 ft. lbs. (35 Nm)
     
    Clutch release bearing
     
    Release fork
     
    Left support spring and release fork shaft, 3.0L engine
     
    Clutch disc and cover and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Clutch release cylinder
     
    Valve and spring, 3.0L engine
     
    Union, bolt and gasket and torque the bolt to 17 ft. lbs. (23 Nm)
     
    Insulator, washer and clutch tube and torque the fastener to 11 ft. lbs. (15 Nm)
     
    Fluid line bracket and torque the bolt to 14 ft. lbs. (19 Nm)
     
    Negative battery cable
     

  2.  
  3. Check and top off the fluid level, if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Clutch fluid line bracket
     
    Insulator, washer and clutch tube
     
    Union, union bolt and gasket
     
    Valve and spring, 3.0L engine
     
    Clutch release cylinder
     
    Clutch cover and disc
     
    Release fork shaft, 3.0L engine
     
    Left support spring, 3.0L engine
     
    Release fork
     
    Clutch release bearing
     
    Release fork boot and fulcrum, 2.4L engine
     
    Release fork boot and maintenance cover, 3.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the clutch assembly-3.0L engine shown, 2.4L similar

     

  4.  

To install:

  1. Install or connect the following:

    Release fork boot and maintenance cover, 3.0L engine
     
    Release fork boot and fulcrum and torque the fulcrum to 26 ft. lbs. (35 Nm)
     
    Clutch release bearing
     
    Release fork
     
    Left support spring and release fork shaft, 3.0L engine
     
    Clutch disc and cover and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Clutch release cylinder
     
    Valve and spring, 3.0L engine
     
    Union, bolt and gasket and torque the bolt to 17 ft. lbs. (23 Nm)
     
    Insulator, washer and clutch tube and torque the fastener to 11 ft. lbs. (15 Nm)
     
    Fluid line bracket and torque the bolt to 14 ft. lbs. (19 Nm)
     
    Negative battery cable
     

  2.  
  3. Check and top off the fluid level, if necessary.
  4.  

 
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