Chrysler Full-Size Vans 1967-1988 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL AND INSTALLATION



With Mechanical Linkage

See Figures 1 through 12

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Fig. Fig. 1: Clutch and flywheel matchmarking



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Fig. Fig. 2: Clutch fork and throwout bearing lubrication points for 1969-86 vehicles



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Fig. Fig. 3: Release fork, bearing and carrier for 1987-88 vehicles



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Fig. Fig. 4: Clutch disc-to-pilot bushing alignment using an old drive pinion from a transmission



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Fig. Fig. 5: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 6: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 7: Check across the flywheel surface, it should be flat



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Fig. Fig. 8: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 9: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 10: Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts



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Fig. Fig. 11: Check the pressure plate for excessive wear



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Fig. Fig. 12: Be sure that the flywheel surface is clean, before installing the clutch

  1. Support the engine on a suitable jack.
  2.  
  3. Remove crossmember.
  4.  
  5. Remove transmission.
  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.  
  11. Mark clutch cover and flywheel, with a suitable tool to assure correct reassembly.
  12.  
  13. Remove clutch cover retaining bolts, loosening them evenly so clutch cover will not be distorted.
  14.  
  15. Pull pressure plate assembly clear of flywheel and, while supporting pressure plate, slide clutch disc from between flywheel and pressure plate.
  16.  

To install:

See Figures 13 through 20

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Fig. Fig. 13: Typical clutch alignment tool, note how the splines match the transmission's input shaft



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Fig. Fig. 14: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 15: Clutch plate installed with the arbor in place



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Fig. Fig. 16: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 17: Pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 18: You may want to use a thread locking compound on the clutch assembly bolts



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Fig. Fig. 19: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 20: Be sure to use a torque wrench to tighten all bolts

  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 and slide clutch disc into position.
  8.  
  9. Position 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 clutch cover until the punch marks on cover and flywheel line up.
  12.  
  13. Bolt cover loosely to flywheel. Tighten cover bolts a few turns at a time, in progression, until tight. Then tighten bolts to 20 ft. lbs. torque.
  14.  
  15. Install transmission.
  16.  
  17. Install frame crossmembers and insulator, tighten all bolts.
  18.  

With Hydraulic Clutch

  1. Remove transmission.
  2.  
  3. Remove clutch housing.
  4.  
  5. Remove clutch fork and release bearing assembly.
  6.  
  7. Mark clutch cover and flywheel, with a suitable tool to assure correct reassembly.
  8.  
  9. Remove the pressure plate retaining bolts, loosening them evenly so the clutch cover will not be distorted.
  10.  
  11. Pull pressure plate assembly clear of flywheel and, while supporting pressure plate, slide clutch disc from between flywheel and pressure plate.
  12.  

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 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 and slide clutch disc into position.
  8.  
  9. Position 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 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:
  14.  



5 / 16 " bolts: 20 ft. lbs.
 
3 / 8 " bolts: 30 ft. lbs.
 

  1. Install transmission.
  2.  
  3. Install frame crossmembers and insulator, tighten all bolts.
  4.  

MECHANICAL LINKAGE ADJUSTMENT



See Figures 21, 22, 23 and 24

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Fig. Fig. 21: Clutch and brake pedal assembly for 1967 vehicles



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Fig. Fig. 22: Clutch/brake pedal assembly and related components for 100/200 series 1968 vehicles



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Fig. Fig. 23: Clutch pedal assembly and related components for 1969-86 vehicles



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Fig. Fig. 24: Exploded view of the torque shaft and linkage for 1977-86 vehicles

The only adjustment required is pedal free-play. Adjust the clutch actuating fork rod by turning the self-locking adjusting nut to provide 1 / 8 " free movement at the end of the fork. This will provide the recommended 1 1 / 2 " free-play at the pedal.

 
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