Ram B1500, B2500, B3500, 1999-2003

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  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

    Click image to see an enlarged view

    Fig. Pressure plate torque sequence

     

  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) for 2001; 37 ft. lbs. (50 Nm) for 2002-04 V6 and V8, or 23 ft. lbs. (30 Nm).
     
    Transmission
     
    Transfer case, if equipped
     
    Negative battery cable
     

  2.  

  1. Remove the transmission and transfer case, if fitted.
  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. Insert a clutch alignment tool in the clutch disc and into the pilot bushing. The tool will hold the disc in place when the cover bolts are removed.
  10.  
  11. Remove the pressure plate retaining bolts, loosening them evenly so the clutch cover will not be distorted.
  12.  
  13. 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.
  14.  

To install:

  1. Note the following points:
    1. Check the flywheel surface for scoring. Scuff sand with 180-grit emery cloth to remove minor scratches and glazing.
    2.  
    3. Machining the flywheel is NOT recommended, although a surface grinder can be used. If score marks are deeper than 0.003 in. (0.076mm), replace the component.
    4.  
    5. Maximum allowable flywheel runout is 0.003 in. (0.08 mm).
    6.  

  2.  
  3. Thoroughly clean all working surfaces of the flywheel and pressure plate.
  4.  
  5. Check runout and free operation of new clutch disc.
  6.  
  7. Insert the alignment tool into the clutch disc hub.
  8.  
  9. Check that the disc hub is positioned correctly. The raised side of the hub faces away from the flywheel. "FLYWHEEL SIDE" may be stamped on the surface.
  10.  
  11. Lubricate the pilot bearing with high-temperature bearing grease.
  12.  
  13. Position clutch disc and plate against flywheel and insert clutch alignment tool through clutch disc hub and into main drive pilot bearing.
  14.  
  15. Rotate clutch cover until the punch marks on cover and flywheel line up.
  16.  
  17. Bolt the cover loosely to flywheel. Tighten the bolts a few turns at a time, in progression, until tight. This is necessary to avoid distortion. Then tighten the 5 / 16 in. bolts to 17 ft. lbs. (23 Nm) and the 3 / 8 in. bolts to 30 ft. lbs. (41 Nm).
  18.  
  19. Remove the release lever and bearing from the clutch housing. Apply high temperature bearing grease to the bore of the release bearing and lever contact surfaces.
  20.  
  21. Apply a light coat of high temperature bearing grease to the transmission shaft splines and release bearing slide surface.
  22.  
  23. Install the release lever and bearing. Be sure that the spring clips that retain the fork on the pivot ball and release bearing on fork are properly installed. On some versions, the lever part number will be towards the bottom of the transmission and right side up. The stamped "I" goes to the pivot ball side of the transmission.
  24.  
  25. Install the clutch housing.
  26.  
  27. Install the transmission.
  28.  



Click image to see an enlarged view

Fig. Release bearing and release fork assembly



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Fig. Matchmark the clutch cover and flywheel



Click image to see an enlarged view

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



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



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



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



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



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



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



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Fig. Check the pressure plate for excessive wear



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



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



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Fig. Aligning the clutch disc



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Fig. Correct clutch disc position



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Fig. Clutch plate installed with the arbor in place



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



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



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



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



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



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Fig. Input shaft lubrication points



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Fig. Release fork and bearing spring clip position

 
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