Dakota, 2001-2005

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transfer case, if equipped
     
    Transmission
     
    Pressure plate. Loosen the bolts evenly in 1 / 2 turn steps.
     
    Clutch disc
     

  4.  

To install:

  1. Install or connect the following:

    Clutch disc and pressure plate. Tighten the pressure plate bolts evenly in 1 / 2 turns to 21 ft. lbs. (28 Nm).
     
    Transmission
     
    Transfer case, if equipped
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Pressure plate torque sequence

     

  2.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise vehicle.
  4.  
  5. Remove transmission and clutch housing as assembly.
  6.  
  7. If pressure plate is being removed for access to another component, mark position of pressure plate cover on flywheel with small punch marks.
  8.  
  9. Loosen pressure plate cover bolts evenly and in rotation to relieve spring tension. Loosen bolts a few threads at a time to avoid warping cover.
  10.  
  11. Remove cover bolts, pressure plate and clutch disc.

    Click image to see an enlarged view

    Fig. Clutch installation. (1) flywheel, (2) pressure plate, (3) alignment tool

  12.  

To install:


NOTE
Clean flywheel surface with solvent. Scuff sand surface with 120/180 grit emery cloth to remove minor scratches and glazing.

  1. Check new clutch disc for runout and free operation on input shaft splines.
  2.  
  3. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease.
  4.  
  5. Position clutch disc on the flywheel.
  6.  
  7. Insert alignment tool or spare input shaft through clutch disc and into pilot bearing.
  8.  
  9. Verify that disc hub is positioned correctly. The raised portion of the hub faces away from the flywheel.
  10.  
  11. Position pressure plate cover over disc and on flywheel.
  12.  
  13. Install cover bolts finger tight.
  14.  
  15. Tighten cover bolts evenly (and in rotation) a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover.
  16.  
  17. Tighten cover bolts to:

    5 / 16 in. bolts to 23 Nm (17 ft. lbs.).
     
    3 / 8 in. bolts to 41 Nm (30 ft. lbs.).
     

  18.  
  19. Apply light coat of high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of front bearing retainer.
    NOTE
    Do not over-lubricate shaft splines. This could result in grease contamination of disc.

  20.  
  21. Install transmission as assembly.
  22.  

 
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