REMOVAL & INSTALLATION
Stratus and Breeze
See Figure 1
The transaxle assembly must be removed to service the clutch assembly.
- Disconnect the negative battery cable from the left strut tower. 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.
- Raise and safely support the vehicle.
- Disconnect the starter wiring and remove the starter assembly.
- Remove the rear and front transaxle support brackets.
- Remove the clutch inspection cover.
- Remove the bolts attaching the modular clutch to the flywheel.
- Remove the transaxle assembly with the clutch as an assembly.
- Remove the clutch assembly from the input shaft of the transaxle.
- 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.
- Examine the throwout or clutch release bearing. It is prelubricated 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.
- 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. Make 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.
- 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.
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 off the rust and apply a light coating 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.
- Install the modular clutch assembly onto the input shaft of the transaxle.
- Install the transaxle assembly, as described earlier in this section.
- Install new clutch-to-driveplate (flywheel) bolts. Tighten the bolts to 55 ft. lbs. (75 Nm) in a crisscross pattern, a few turns at a time to prevent distortion of the flywheel.
- Install the clutch inspection cover.
- Install the transaxle lower support brackets.
- Install the starter assembly.
- Lower the vehicle. Connect the negative battery cable.
- Road test the vehicle to check for proper clutch operation.
Sebring Coupe and Avenger
See Figure 2
- Disconnect the negative battery cable.
- Raise and safely support the vehicle.
- Remove the transaxle assembly from the vehicle, as described earlier in this section.
The modular clutch assembly used in these vehicles consists of a single, dry-type clutch disc and a diaphragm style clutch cover. The clutch unit is serviced as an assembly; no disassembly is possible.
- Remove the pressure plate attaching bolts, pressure plate and clutch disc. If the pressure plate is to be reused, loosen the bolts in a diagonal pattern, 1 or 2 turns at a time. This will prevent warping the clutch cover assembly.
- Remove the return clip and the pressure plate release bearing. Do not use solvent to clean the bearing.
- Inspect the clutch release fork and fulcrum for damage or wear. If necessary, remove the release fork and the fulcrum from the transaxle.
- Carefully inspect the condition of the clutch components and replace any worn or damaged parts.
- Inspect the flywheel for heat damage or cracks. Resurface or replace the flywheel as required. Install the flywheel using new bolts.
- Install the fulcrum, if removed, and tighten. Install the release fork. 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 to the pushrod hole in the release fork.
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.
- 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.
- Apply a coating of grease to the clutch disc splines and then use a brush to rub it in the grooves. Using a universal 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 to 55 ft. lbs. (75 Nm).
- Install the transaxle assembly, as described earlier in this section, and check the fluid level.
- Verify proper clutch operation.
Stratus and Breeze
See Figure 3
The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located with the clutch cable assembly. 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. No manual adjustment is obtainable.
When servicing this vehicle or if removing and installing the clutch cable, do not pull on the clutch cable housing to remove it from the dashboard panel. Damage to the cable self-adjuster may occur.
To check the function of the adjuster mechanism, use the following procedure:
- With slight pressure, pull the clutch release lever end of the cable to draw the cable taut.
- Push the clutch cable housing toward the dashboard panel. With less than 25 lbs. of effort, the cable housing should move 1.2-2.0 inches (30-50mm). This indicates proper adjuster mechanism function.
- If the cable does not adjust, determine if the mechanism is properly seated on the bracket.
See Figures 4, 5 and 6
- With the carpet under the clutch pedal turned back, measure the clutch pedal height from the face of the pedal pad to the firewall. Compare the measured value with the desired distance of 7.00-7.09 inches (175-180mm).
- Measure the clutch pedal clevis pin play at the face of the pedal pad. Press the pedal lightly until resistance is met, and measure this distance. The clutch pedal clevis pin play should be within 0.040-0.120 inch (1-3mm).
If the clutch pedal height and/or clevis pin play are not within specifications, adjust as follows:
- For vehicles without cruise control, turn and adjust the stop bolt so the pedal height is within specifications, then tighten the locknut.
- For vehicles with an auto-cruise control system, unfasten the clutch switch connector and turn the switch to obtain the specified clutch pedal height. Hold this setting by tightening the locknut.
- Turn the pushrod to adjust the clutch pedal clevis pin play within specifications, then secure the pushrod with the locknut.
When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to force the pushrod toward the master cylinder.
- Check that when the clutch pedal is depressed all the way, the interlock switch changes from ON to OFF .
- Move the clutch pedal until the resistance begins to increase; measure between this point and the pedal resting point, to determine the clutch pedal free-play. The clutch pedal free-play measurement should be 0.240-0.510 inch (6-13mm). With the pedal fully disengaged, check the distance between the firewall and the top of the pedal pad. The measurement should be 2.760 inches (70mm) or more.
- If the measurements are not within specification, bleed the clutch hydraulic system. If, after bleeding, the measurements are still not within the specified range, the master cylinder or clutch must be replaced.