Chrysler Full-Size Trucks 1967-1988 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



Mechanical Linkage

See Figures 1 through 5

  1. Support the engine on a suitable jack.
  2.  
  3. Remove crossmember.
  4.  
  5. Remove transmission. Remove transfer case, if equipped.
  6.  
  7. Remove clutch housing pan if so equipped.
  8.  
  9. Remove clutch fork, clutch bearing and sleeve assembly if not removed with transmission.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Release fork, bearing and carrier

  1. Matchmark clutch cover and flywheel. to assure correct reassembly.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Always matchmark the clutch cover and flywheel for removal and installation

  1. Remove clutch cover retaining bolts, loosening them evenly so clutch cover will not be distorted.
  2.  


CAUTION
Clutch disc may contain asbestos. Do NOT use compressed air to clean components. Instead use a commercially available evaporative spray cleaner.

  1. Pull the pressure plate assembly clear of flywheel and, while supporting the pressure plate, slide the clutch disc from between the flywheel and pressure plate.
  2.  

To install:
  1. Thoroughly clean all working surfaces of the flywheel and the pressure plate.
  2.  
  3. Grease radius at back of bushing.
  4.  
  5. Rotate clutch cover and pressure plate assembly for maximum clearance between flywheel and frame crossmember if crossmember was not removed during clutch removal.
  6.  
  7. Tilt the top edge of clutch cover and pressure plate assembly back and move it up into the clutch housing. Support the clutch cover and pressure plate assembly and slide clutch disc into position.
  8.  
  9. Position the clutch disc and plate against flywheel and insert spare transmission main drive gear shaft or clutch installing tool through clutch disc hub and into main drive pilot bearing.
  10.  
  11. Rotate the clutch cover until the punch marks on cover and flywheel align.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Notice the location of the punch marks

  1. Bolt the cover loosely to flywheel. Tighten the cover bolts a few turns at a time, in progression, until tight. Then tighten bolts to 20 ft. lbs. (27 Nm) torque.
  2.  
  3. Apply grease to the release fork pads of the carrier. Lubricate the fork fingers and retaining spring at the pivot contact area points.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: 1969-86 Lubrication points

  1. Engage the fork fingers under clutch carrier retaining springs while engaging the fork spring into the fork pivot. Be sure the groove of the dust seal is engaged on the seal opening flange in clutch housing.
  2.  
  3. Insert the threaded end of the fork rod assembly into the hole end of the release fork. Install the eye end of the fork rod on torque shaft lever pin and secure with spring washer.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the torque shaft and linkage

  1. Install the return spring to the clutch release fork and clutch housing.
  2.  

Do not lubricate the splines or pilot end of transmission drive pinon. when installing the transmission. These areas must be kept dry.

  1. Install the transmission and transfer case, if so equipped.
  2.  
  3. Install the frame crossmembers and insulator, tighten all bolts.
  4.  
  5. Adjust clutch linkage.
  6.  

Hydraulic Clutch

See Figure 6

  1. Remove the transmission. Remove transfer case, if equipped.
  2.  
  3. Remove the clutch housing.
  4.  
  5. Remove the clutch fork and release bearing assembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: 1987-88 clutch fork and bearing setup

  1. Mark the clutch cover and flywheel, with a suitable tool to assure correct reassembly.
  2.  
  3. Remove the pressure plate retaining bolts, loosening them evenly so the clutch cover will not be distorted.
  4.  
  5. Pull the pressure plate assembly clear of flywheel and, while the supporting pressure plate, slide the clutch disc from between flywheel and plate.
  6.  

To install:

CAUTION
Clutch disc may contain asbestos. Do NOT use compressed air to clean components. Instead use a commercially available evaporative spray cleaner.

  1. Thoroughly clean all working surfaces of the flywheel and the pressure plate.
  2.  
  3. Grease radius at back of bushing.
  4.  
  5. Rotate clutch cover and pressure plate assembly for maximum clearance between flywheel and frame crossmember (if crossmember was not removed during clutch removal).
  6.  
  7. Tilt top edge of clutch cover and pressure plate assembly back and move it up into the clutch housing. Support clutch cover and pressure plate assembly, then slide clutch disc into position.
  8.  
  9. Position the clutch disc and the plate against the flywheel, then insert spare transmission main drive gear shaft or clutch installing tool through clutch disc hub and into main drive pilot bearing.
  10.  
  11. Rotate clutch cover until the punch marks on cover and flywheel line up.
  12.  
  13. Bolt the pressure plate loosely to flywheel. Tighten the bolts a few turns at a time, in progression, until tight. Then tighten bolts to:

    5 / 16 in. (8mm) bolts: 20 ft. lbs. (27 Nm)
     
    3 / 8 in. (9.5mm) bolts: 30 ft. lbs. (40 Nm)
     

  14.  
  15. Install transmission.
  16.  
  17. Install frame crossmembers and insulator, tighten all bolts.
  18.  

 
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