REMOVAL & INSTALLATION
See Figures 1 and 2
Chrysler recommends the use of special tool C-4676 for disc alignment. Clean the flywheel face with crocus cloth or fine sandpaper (400-600 grade), then wipe the surface with mineral spirits. If the flywheel surface is severely scored, heat cracked or warped, replace the flywheel. Always replace the clutch assembly, pressure plate and release bearing as a matched set.
- Disconnect the negative battery cable. Remove the transaxle as described earlier in this section.
- Matchmark the clutch cover and flywheel for installation in the same positions.
- Insert special tool C-4676 (or its equivalent) through the clutch disc hub to prevent the clutch disc from falling and damaging the facings.
- Loosen the cover attaching bolts. Do this in a crosswise pattern, a few turns at a time to prevent warping the cover.
- Remove the cover assembly and disc from the flywheel. Be careful to keep any dirt or other contamination off the friction surfaces.
- Remove the clutch release shaft and slide the release bearing off the input shaft seal retainer.
- Remove the fork from the release bearing thrust plate.
Inspect the rear main seal for leakage. Repair the seal at this point, if there is leakage, perform the following:
- Make sure the friction surfaces of both the flywheel and the pressure plate are uniform in appearance. If there is evidence of heavy contact at one point and very light contact 180° away, the flywheel or pressure plate may be improperly mounted (tightened) or sprung due to mechanical damage.
- If there is evidence that the flywheel may not be true, it should be checked with a dial indicator or replaced (always replace the flywheel retaining bolts-with new bolts coated with Loctite® sealant-tighten to specifications).
- The indicator must be mounted so that its plunger is in contact with the flywheel wear circle. In a full turn, the indicator should read no more than 0.003 in. (0.076mm).
- Make sure to push forward on the flywheel before you begin taking the reading, zeroing the indicator and continuously as you turn it (to keep any crankshaft end-play out of the reading-refer to a local machine shop if necessary, because the flywheel assembly can be machined if still in specifications).
- With a straightedge, check the pressure plate for flatness. The inner surface of the pressure plate should be straight within 0.020 in. (0.5mm). It should also be free of discoloration, cracks, grooves, or ridges. Otherwise, replace it.
- Spin the clutch bearing to make sure it turns freely and smoothly.
- Install the fork, release bearing, and clutch release shaft in the reverse order of the removal procedure.
- Install the clutch assembly onto the flywheel, carefully aligning the dowels on the flywheel with the holes in the assembly. Make sure the alignment marks made earlier also align. Then, apply pressure to the clutch alignment tool to precisely center it as you snug the clutch attaching bolts sufficiently to hold the clutch disc in the proper position.
- Tighten the clutch cover bolts alternately and evenly until they all are seated. Then, tighten to 21 ft. lbs. (29 Nm). Remove the disc alignment tool.
- Install the transaxle as described earlier in this section.