Chrysler Full-Size Trucks 1989-1996 Repair Guide



Because of the way an internal combustion engine breathes, it can produce torque (or twisting force) only within a narrow speed range. Modern Overhead Valve (OHV) pushrod engines must turn at about 2500 rpm to produce their peak torque. Often by 4500 rpm, they are producing so little torque that continued increases in engine speed produce no power increases.

The torque peak on overhead camshaft engines is, generally, much higher, but much narrower.

The manual transmission and clutch are employed to vary the relationship between engine RPM and the speed of the wheels so that adequate power can be produced under all circumstances. The clutch allows engine torque to be applied to the transmission input shaft gradually, due to mechanical slippage. The truck can, consequently, be started smoothly from a full stop.

The transmission changes the ratio between the rotating speeds of the engine and the wheels by the use of gears. 4-speed or 5-speed transmissions are most common. The lower gears allow full engine power to be applied to the rear wheels during acceleration at low speeds.

The clutch driveplate is a thin disc, the center of which is splined to the transmission input shaft. Both sides of the disc are covered with a layer of material which is similar to brake lining and which is capable of allowing slippage without roughness or excessive noise.

The clutch cover is bolted to the engine flywheel and incorporates a diaphragm spring which provides the pressure to engage the clutch. The cover also houses the pressure plate. When the clutch pedal is released, the driven disc is sandwiched between the pressure plate and the smooth surface of the flywheel, thus forcing the disc to turn at the same speed as the engine crankshaft.

The transmission contains a mainshaft which passes all the way through the transmission, from the clutch to the driveshaft. This shaft is separated at one point, so that front and rear portions can turn at different speeds.

Power is transmitted by a countershaft in the lower gears and reverse. The gears of the countershaft mesh with gears on the mainshaft, allowing power to be carried from one to the other. All the countershaft gears are integral with that shaft, while several of the mainshaft gears can either rotate independently of the shaft or be locked to it. Shifting from one gear to the next causes one of the gears to be freed from rotating with the shaft and locks another to it. Gears are locked and unlocked by internal dog clutches which slide between the center of the gear and the shaft. The forward gears usually employ synchronizers; friction members which smoothly bring gear and shaft to the same speed before the toothed dog clutches are engaged. The clutch is operating properly if:

  1. It will stall the engine when released with the vehicle held stationary.
  3. The shift lever can be moved freely between 1st and reverse gears when the vehicle is stationary and the clutch disengaged.

A clutch pedal free-play adjustment is incorporated in the linkage. If there is about 1-2 in. (25-50mm) of motion before the pedal begins to release the clutch, it is adjusted properly. Inadequate free-play wears all parts of the clutch releasing mechanisms and may cause slippage. Excessive free-play may cause inadequate release and hard shifting of gears.

Some clutches use a hydraulic system in place of mechanical linkage. If the clutch fails to release, fill the clutch master cylinder with fluid to the proper level and pump the clutch pedal to fill the system with fluid. Bleed the system in the same way as a brake system. If leaks are located, tighten loose connections or overhaul the master and/or slave cylinder as necessary.