PT Cruiser, 2001 - 2005

Driven Disc & Pressure Plate

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Removal & Installation



  1. Remove transaxle assembly.
  2.  
  3. Mark position of pressure plate on flywheel with paint or a scriber for assembly reference.
  4.  
  5. Loosen and remove six pressure plate-to-flywheel bolts. Remove pressure plate and clutch disc.
  6.  
  7. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly.

    Click image to see an enlarged view

    Fig. Clutch disc and pressure plate assembly

  8.  

To install:

  1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The release bearing is integral to the Concentric Slave Cylinder (CSC).
  2.  
  3. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed.
  4.  
  5. Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel onto the engine crankshaft.
  6.  
  7. Install flywheel to crankshaft. Install eight flywheel-to-crankshaft bolts and torque to 33 ft. lbs. (45 Nm) plus an additional ¼ turn (90°).
  8.  
  9. Apply a very light coating of grease to the splines in the clutch disc hub.
  10.  
  11. Position the clutch disc to the flywheel. Make sure the side marked -FLYWHEEL SIDE- faces the flywheel.
  12.  
  13. Install the clutch pressure plate to the flywheel and clutch disc. Finger-tighten the six pressure plate-to-flywheel bolts.
  14.  
  15. Use Clutch Alignment Tool 6724 to position the clutch disc to the center of the flywheel.
  16.  
  17. Tighten pressure plate bolts evenly and in rotation a few threads at a time. The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate.
  18.  
  19. Using a -criss-cross- pattern, torque pressure plate bolts to 23 ft. lbs. (31 Nm).
  20.  
  21. Remove the clutch disc alignment tool.
  22.  
  23. Apply light coat of Mopar® High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft.
    CAUTION
    Do not over lubricate shaft splines. This will result in grease contamination of disc.

  24.  
  25. Install transaxle.
  26.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Battery and tray
     
    Back-up lamp electrical connector
     
    Shift cable-to-bracket clips
     
    Shift lever and crossover cable from the levers. Move the cables out of the way.
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Clutch master cylinder tube from the slave cylinder using a clutch hydraulic quick connect Tool 6638A
     
    Both halfshafts
     
    Power steering hose from the structural collar
     
    Left side lateral bending brace and structural collar
     
    Bell housing dust cover
     
    Right side lateral bending brace
     
    Starter
     
    Driveplate-to-clutch module bolts and support the engine at the oil pan
     
    Transaxle upper mount bolts and lower the engine/transaxle assembly
     
    Modular clutch from the input shaft

    Click image to see an enlarged view

    Fig. Exploded view of the modular clutch assembly

     

  4.  

To install:

  1. Install or connect the following:

    Clutch module to the input shaft
     
    Transaxle-to-engine mount bolts and torque them to 80 ft. lbs. (108 Nm)
     
    Upper mount bolts and torque them to 65 ft. lbs. (88 Nm)
     
    Driveplate-to-clutch module bolts and torque them to 65 ft. lbs. (88 Nm)
     
    Starter and torque the bolts to 40 ft. lbs. (54 Nm). Make certain that the ground cable is fastened to the upper bolt.
     
    Starter electrical connectors
     
    Bell housing dust cover
     
    Left side lateral bending brace and structural collar
     
    Power steering hose to the structural collar
     
    Right side lateral bending brace and torque the bolts to 60 ft. lbs. (81 Nm)
     
    Both halfshafts
     
    Clutch master cylinder tube to the slave cylinder
     
    VSS electrical connector
     
    Back-up lamp switch electrical connector
     
    Air cleaner assembly
     
    Battery and tray
     
    Battery cables
     

  2.  
  3. Fill the transmission to the proper level.
  4.  
  5. Road test the vehicle and check for proper clutch operation.
  6.  
  7. Check the fluid level and adjust if needed.
  8.  

 
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