Chrysler PT Cruiser. Manual — part 448
(17) Connect battery negative cable.
(18) Install air cleaner assembly (Fig. 76).
(19) Verify that brake master cylinder reservoir is
full. Top off with DOT 3 brake fluid if necessary.
(20) Actuate clutch pedal a minimum of fifty times
to allow any air ingested into the system to vent to
the master cylinder reservoir. If residual air becomes
trapped in the system, it is necessary to bleed the
clutch hydraulic system. (Refer to 6 - CLUTCH -
STANDARD PROCEDURE)
(21) Verify proper clutch release system operation.
MODULAR CLUTCH
DESCRIPTION
2.4L MODELS (Except Turbo)
The modular clutch assembly (Fig. 77) is located
between the engine and manual transaxle in the
transaxle bellhousing, and is responsible for trans-
mitting engine power to the transaxle. The modular
clutch is an assembly which incorporates a self-ad-
justing design and consists of the following compo-
nents:
• Flywheel
• Clutch Disc
• Pressure Plate
• Diaphragm Spring
• Adjusting Ring
• Sensor
• Cover
2.4L TURBO MODELS
Models equipped with the 2.4L Turbo Engine
option also utilize a modular clutch assembly, how-
ever, this application incorporates a Dual-Mass Fly-
wheel (DMF), is not of a self-adjusting design, and is
serviceable.
Fig. 76 Air Cleaner Assembly Removal/Installation
1 - AIR CLEANER ASSEMBLY
Fig. 77 Modular Clutch Assembly—Typical
1 - MODULAR CLUTCH ASSEMBLY
6 - 36
CLUTCH
PT
MASTER CYLINDER - RHD (Continued)
OPERATION
The modular clutch assembly is designed to trans-
mit power from the engine to the manual transaxle.
This is accomplished by the friction and clamping
force generated when the spring loaded pressure
plate locks the clutch disc to the flywheel (Fig. 78).
The clutch disc, which is splined to the transaxle
input shaft, transmits power until the center of the
diaphragm spring is depressed, and the clamp force
is removed from the disc. The self -adjusting feature
of this clutch assembly relies on the sensor ring and
the adjuster ring (Fig. 79) , which works its way
around a ramped clutch cover, taking up clearance as
the clutch disc wears and maintaining diaphragm
spring force throughout the life of the clutch. The pri-
mary benefits of this design are reduced pedal effort,
constant release load over clutch life, and extended
clutch life.
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove modular clutch assembly (Fig. 80) from
transaxle input shaft.
(3) 2.4L Turbo models: Disassemble modular
clutch assembly. Remove six (6) pressure plate-to-fly-
wheel bolts (Fig. 81). Remove pressure plate and disc
from flywheel.
INSPECTION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty opera-
tion.
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, or water/
road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main
seal and/or transaxle input shaft. Oil leaks produce a
residue of oil on the transaxle housing interior, clutch
cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-
lubrication. During clutch service, apply only a small
amount of grease to the input shaft splines. Excess
grease may be thrown off during operation, contami-
nating the disc.
Fig. 78 Clutch Coupling Powerflow - Typical
Fig. 79 Modular Clutch Assembly Components—
Typical
1 - FLYWHEEL
2 - COVER
3 - PRESSURE PLATE
4 - SENSOR RING
5 - ADJUSTING RING
6 - DIAPHRAGM SPRING
7 - DISC
PT
CLUTCH
6 - 37
MODULAR CLUTCH (Continued)
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by
driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing
clutch components to become contaminated. Facing of
disc will absorb moisture and bond to the flywheel
and/or, pressure plate, if vehicle is allowed to stand
for some time before use. If this condition occurs,
replacement of clutch assembly may be required.
Drive the vehicle until normal clutch operating tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
Fig. 80 Modular Clutch Assembly—Typical
1 - MODULAR CLUTCH ASSEMBLY
2 - CLIP
3 - TRANSAXLE
4 - CLUTCH MODULE BOLT (4)
Fig. 81 Pressure Plate-to-Flywheel Bolts—Turbo
1 - BOLT (6)
2 - PRESSURE PLATE
3 - DOWEL
6 - 38
CLUTCH
PT
MODULAR CLUTCH (Continued)
INSTALLATION
(1) 2.4L Turbo models: Install clutch disc to fly-
wheel with “Flywheel Side” oriented towards fly-
wheel. Align clutch disc to flywheel by ensuring equal
distance between disc and flywheel lip exists in three
places as shown in (Fig. 82). Install pressure plate to
flywheel, locating on dowels (Fig. 81) and making
sure not to disturb clutch disc. Install and torque six
(6) pressure plate-to-flywheel bolts to 28 N·m (250 in.
lbs.). Visually verify clutch disc alignment.
(2) All models: Install clutch module (Fig. 80)
onto input shaft.
(3) Install transaxle into vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
SLAVE CYLINDER
DESCRIPTION
1.6/2.4L MODELS (Except Diesel & Turbo)
The clutch slave cylinder consists of a hydraulic
piston and cylinder, seal and return spring. It is fas-
tened to the transaxle bellhousing as shown in (Fig.
83) (Fig. 84). The slave cylinder is connected to the
clutch master cylinder hydraulic pipe, which is
retained to the cylinder by a pair of retainer clips,
and utilizes a bleed port to facilitate the removal of
air from the system.
Fig. 82 Clutch Disc-to-Flywheel Orientation
1 - FLYWHEEL
2 - CLUTCH DISC
L
- EQUAL DISTANCE FOR ALIGNMENT
Fig. 83 Clutch Slave Cylinder at Transaxle- 1.6L
Models
1 - SLAVE CYLINDER
2 - BOLT
Fig. 84 Clutch Slave Cylinder at Transaxle- 2.4L
Models
1 - SLAVE CYLINDER
2 - BRACKET
PT
CLUTCH
6 - 39
MODULAR CLUTCH (Continued)
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