Chrysler Full-Size Vans 1989-1998 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 and 16



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Fig. Fig. 1: Typical clutch alignment tool; note how the splines match the transmission's input shaft



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 4: Check across the flywheel surface; it should be flat



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Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order to replace it or have it machined



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Fig. Fig. 7: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts



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Fig. Fig. 8: Check the pressure plate for excessive wear



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Fig. Fig. 9: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 10: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 11: Clutch plate installed with the arbor in place



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Fig. Fig. 12: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 13: The pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 14: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 15: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 16: Be sure to use a torque wrench to accurately tighten all bolts

  1. Remove the transmission.
  2.  
  3. Remove the clutch housing.
  4.  
  5. Remove the clutch fork and release bearing assembly.
  6.  
  7. Matchmark the clutch cover and flywheel for installation reference.
  8.  
  9. Remove the pressure plate retaining bolts, loosening them evenly so the clutch cover will not be distorted.
  10.  
  11. Pull the pressure plate assembly clear of the flywheel and, while supporting the pressure plate, slide the clutch disc from between the flywheel and pressure plate.
  12.  

To install:
  1. Thoroughly clean all working surfaces of the flywheel and 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 the clutch cover and pressure plate assembly and slide clutch disc into position.
  8.  
  9. Position clutch disc and plate against flywheel and insert clutch alignment 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 the 5 / 9 in. bolts to 13 ft. lbs. (27 Nm) and the 3 / 1 in. bolts to 30 ft. lbs. (41 Nm).
  14.  
  15. Install the transmission.
  16.  

ADJUSTMENTS



All vehicles are equipped with a hydraulic operating linkage system. No adjustment is required. The hydraulic linkage system is serviced as an assembly only. The individual components that form the system cannot be overhauled or serviced separately.

 
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