REMOVAL & INSTALLATION
See Figures 1 through 12
- Remove the transmission.
- Insert the forward end of an old transmission input shaft or a clutch disc guide tool into the splined center of the clutch disc. This will keep the disc from dropping when the pressure plate is removed from the flywheel.
- Loosen the clutch mounting bolts alternately and diagonally in very small increments (no more than two turns at a time) so as to avoid warping the cover flange. When all bolts are free, remove the pressure plate and disc.
- Remove the return clip and then remove the release bearing.
- Use a center punch and hammer to remove the spring pins from the clutch release fork and shaft. Discard the spring pins; they are not reusable.
- Remove the release shaft. Remove the release fork, seals, and return spring.
- Before installing the clutch, pack the release fork fulcrum hole and slave cylinder pushrod hole with grease. Also pack grease into the groove on the inside diameter of the throwout bearing.
- Wipe all friction surfaces of the clutch disc, pressure plate, and flywheel to remove any grease or oil. Lightly grease the clutch disc splines and transmission input shaft splines.
- Locate the clutch disc on the flywheel with the stamped mark facing outward. Use a clutch disc guide or old input shaft to center the disc on the flywheel, and then install the pressure plate over it. Install the bolts and tighten them evenly. Torque to 18 Nm (13 ft. lbs.).
- Install the transmission in reverse of removal, making sure the input shaft is lined up properly to avoid bending it.
1990-93 Models See Figures 3 through 12
The 1990-93 Pick-ups equipped with the 2.4L 4-cylinder engines have cable-actuated clutches and Pick-ups with 3.0L engines are equipped with hydraulic clutches, however the procedures for removing the clutches from the flywheels is the same.
- Remove the transmission. For the procedures for the removal of the transmission, refer to the previously described instructions in this section.
- Remove the clutch cover from the flywheel by unbolting the mounting bolts. Do not allow the clutch disc to fall. If the disc is to be reused, install the clutch disc guide tool before removing the clutch disc.
- Apply the specified grease to the clutch disc splines and squeeze it in place with a brush. The specified grease is Mopar genuine grease Part No. 0101011 or equivalent.
- Use a clutch disc guide to position the disc on the flywheel.
- Slide the clutch cover over the disc guide and install the mounting bolts until finger tight. Tighten the mounting bolts to 14 ft. lbs. (19 Nm) in a crisscross fashion.
- Install the transmission.
ADJUSTMENTS - Pedal Height
1979-82 Models See Figures 13 and 14
- Adjust the pedal height to the standard value with the adjusting bolt, then check the pedal stroke and distance.
Insufficiant pedal; stroke results in only partial clutch release, causing hard gear shifting and gear grinding when shifting.
- In the engine compartment, at the firewall, pull out the clutch cable a little and adjust the cable by turning the adjusting wheel until it is 0.012-0.16 in. (3-4mm) from the insulator.
- Clutch pedal free play should be within 0.8-1.4 in. (20-35mm).
- Measure clutch pedal height from the floor to the top of the pedal pad, along the line of pedal travel. The height should be: 6.5-6.7 in. (16.5-17.0cm)
- Adjust the pedal height, if necessary, by loosening the locknut and turning the adjusting bolt or rotating clutch switch, and retighten the locknut. Now adjust the pedal free-play.
For 1990-93 models, refer to the clutch switch adjustment procedures (described earlier in this section).
When checking pedal play you must not move the pedal far enough to disturb the position of the hydraulic cylinder actuating rod. Move the pedal to a point where resistance stiffens but no more.
- For hydraulic clutches used in later-modeled Pick-ups, loosen the locknut, and turn the pushrod to bring the play within specification. On all models, this is 0.039-0.12 in. (1-3mm). Retighten the locknut.
- Check the total free-play, which should be 0.24-0.47 in. (6-12mm). Check the pedal height, also. If play is not correct, bleed the system. If that does not correct play, the master cylinder or the clutch itself is faulty.
- On models with the clutch cable, the clutch pedal free-play should be 0.79-1.18 in. (20-30mm). If it is outside specification, pull up gently on the cable at the floorboard and turn the outer cable adjusting nut until the nut-to-insulator clearance is about 0.098 in. (2.5mm). After making the adjustment, depress the clutch pedal to the floor several times and recheck pedal free-play.