Ram Truck 1500, 2500 & 3500 (2006-2008)

Driven Disc & Pressure Plate

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Adjustments



Perform the following procedure, when replacing only the clutch disc on Diesel vehicles with Dual Mass Flywheel and self-adjusting pressure plate. The pressure plate must be reset before installing a new disc.

  1. Support pressure plate flange with press blocks on a press.
  2.  
  3. Center press ram on the pressure plate diaphragm spring fingers.
  4.  
  5. Compress the diaphragm spring fingers, until tension is released from the stepped adjusting ring.

    Click image to see an enlarged view

    Fig. Compressing the diaphragm spring fingers

  6.  
  7. Place two screwdrivers against two of the three stepped adjusting ring (1) tension spring stops, just ahead of the adjusting ring tension springs on the pressure plate (2).
  8.  
  9. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until the coil springs are fully compressed. Then hold adjusting ring while releasing the press pressure.

    Click image to see an enlarged view

    Fig. Rotate stepped adjuster rings counterclockwise

  10.  
  11. Remove the screwdrivers.
  12.  
  13. The pressure plate is now adjusted for a new clutch disc.
  14.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts.
  4.  
  5. Remove transmission and transfer case, if equipped.
  6.  
  7. If pressure plate will be reused, mark the position on flywheel with paint or scriber . Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it.
  8.  
  9. Insert clutch alignment tool through pressure plate and into pilot bushing, to hold disc in place while removing bolts.
  10.  
  11. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate.
  12.  
  13. Remove bolts completely and remove pressure plate, disc and alignment tool.
  14.  

To install:


WARNING
Before installing a clutch disc on the Diesel engine with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Refer to clutch disc adjustment for procedure. Failure to reset the pressure will result in damage to the clutch disc.

  1. Check runout and free operation of new clutch disc.
  2.  
  3. Lubricate crankshaft pilot bearing with a NLGI-2 rated grease.
  4.  
  5. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel.
    NOTE
    Flywheel side is imprinted on the disc face.



    Click image to see an enlarged view

    Fig. Clutch alignment tool in clutch disc hub shown

  6.  
  7. Install alignment tool in pilot bearing and position disc on the flywheel.
  8.  
  9. Position pressure plate over disc and onto the flywheel.
    NOTE
    Over the wear life of a clutch disc the pressure plate will loose some of it's clamp load. It is recommended when replacing a worn clutch, the pressure plate is replaced at the same time.

  10.  
  11. Align and hold pressure plate in position and install bolts finger tight.
  12.  
  13. Tighten bolts evenly and a few threads at a time in a diagonal pattern.
    WARNING
    Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover.

  14.  
  15. Tighten pressure plate bolts as follows:

    V6 and V8 Engines-37 ft. lbs. (50 Nm).
     
    Diesel Engines-22 ft. lbs. (30 Nm).
     

  16.  
  17. Remove release lever and release bearing from clutch housing. Apply Mopar® high temperature bearing grease to bore of release bearing, release lever contact surfaces and release lever pivot stud.
  18.  
  19. Apply light coat of Mopar® high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of the transmission front bearing retainer.
    WARNING
    Do not over lubricate shaft splines. This can result in grease contamination of the disc.

  20.  
  21. Wipe pilot bearing surface clean.
  22.  
  23. Install release lever and bearing in clutch housing. Verify spring clips that retain lever on pivot ball and release bearing are installed properly.
    NOTE
    If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped -I- in the lever which goes to the pivot ball side of the transmission.

  24.  
  25. Install transmission and transfer case if equipped.
  26.  
  27. Check fluid level in clutch master cylinder and depress clutch pedal several time.
  28.  

 
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