Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Flywheel or Flexplate & Ring Gear

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General Information



No manual transmissions were offered in model year 2000 vehicles.

Removal & Installation



  1. Remove the transaxle.
  2.  
  3. Mark the alignment of the flexplate to the crankshaft.
  4.  
  5. Remove the flexplate attaching bolts.
  6.  
  7. Remove the flexplate .

    Click image to see an enlarged view

    Fig. Exploded view of spacer (1), spacer bolt (2), flexplate bolts (3) and flexplate (4)-2.4L engine

  8.  

To install:

  1. Position the flexplate on crankshaft and line up alignment marks.
  2.  
  3. Apply MOPAR® Lock & Seal Adhesive, or equivalent, to flexplate bolt threads.
  4.  
  5. Install the flexplate bolts and tighten to 70 ft. lbs. (95 Nm).
  6.  
  7. Install the transaxle.
  8.  

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. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. 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.



    Transaxle
     
    Pressure plate-to-flywheel bolts, pressure plate and clutch disc
     

  6.  
  7. Remove the return clip and the pressure plate release bearing. Do not use solvent to clean the bearing.
  8.  
  9. Inspect the clutch release fork and fulcrum for damage or wear. If necessary, remove the release fork and the fulcrum from the transaxle.
  10.  
  11. Carefully inspect the condition of the clutch components and replace any worn or damaged parts.
    NOTE
    To prevent the engine from turning when removing the flywheel bolts, temporarily install one clutch cover bolt into the flywheel and one transmission bolt into the engine block and secure them together with a piece of scrap metal.


    WARNING
    Do not attempt to disassemble the flywheel. It is precisely balanced and assembled at the factory.

  12.  
  13. Remove the flywheel bolts in a crisscross pattern.
  14.  

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 and torque to 98 ft. lbs. (132 Nm) in a crisscross pattern
     
    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:
    NOTE
    To prevent the engine from turning when removing the flywheel bolts, temporarily install one clutch cover bolt into the flywheel and one transmission bolt into the engine block and secure them together with a piece of scrap metal.


    WARNING
    Do not attempt to disassemble the flywheel. It is precisely balanced and assembled at the factory.



    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
     

  4.  
  5. Remove the flywheel bolts in a crisscross pattern.

    Click image to see an enlarged view

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

  6.  

To install:

  1. Install or connect the following:

    Flywheel and the two bolt cover plates
     
    New flywheel bolts and torque to 54 ft. lbs. (74 Nm) in a crisscross pattern
     
    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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