Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 299
CLUTCH
TABLE OF CONTENTS
page
page
CLUTCH
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - CLUTCH
COVER AND DISC RUNOUT . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - CLASH-INTO-
REVERSE COMPLAINTS . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH PEDAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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CLUTCH PEDAL INTERLOCK SWITCH
DIAGNOSIS AND TESTING - CLUTCH PEDAL
. . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH RELEASE BEARING AND LEVER
. . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH RELEASE CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 10
MODULAR CLUTCH
. . . . . . . . . . . . . . . . . . . . . . . . . 11
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CLUTCH
DESCRIPTION
Manual transaxle equipped models utilize a modu-
lar clutch assembly. The clutch system consists of a
modular clutch assembly (Fig. 1), a sleeve type
release bearing, a self adjusting clutch cable, and a
clutch pedal that is part of a brake/clutch pedal
bracket assembly.
The modular clutch assembly consists of a single,
dry-type clutch disc, a diaphragm style clutch cover,
and an integrated flywheel. The clutch cover is riv-
eted to the flywheel, containing the clutch disc
within. The modular clutch can only be serviced as
an assembly.
Fig. 1 Modular Clutch Assembly
1 - MODULAR CLUTCH ASSEMBLY
JR
CLUTCH
6 - 1
OPERATION
MECHANICAL
The clutch assembly is designed to transmit power
from the engine to the manual transaxle. This is
accomplished by the friction and clamping force gen-
erated when the spring loaded pressure plate locks
the clutch disc to the flywheel (Fig. 2). 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.
CLUTCH RELEASE SYSTEM
A sleeve-type release bearing is used to engage and
disengage the clutch cover pressure plate. The
release bearing is operated by a pivoting release
lever in the clutch housing (Fig. 4). The lever pivots
on a ball stud within the housing. The release lever
is actuated by a self-adjusting clutch cable (Fig. 3).
The clutch cable has a unique self-adjuster mecha-
nism (Fig. 3) built into the cable which compensates
for clutch disc wear. The preload spring maintains
tension on the cable. This tension keeps the clutch
release bearing (Fig. 4) continuously loaded against
the fingers of the clutch cover assembly. The cable
requires no maintenance or lubrication.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH SYSTEM
Clutch problem diagnosis will generally require a
road test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
Fig. 2 Clutch Coupling Powerflow - Typical
Fig. 3 Clutch Cable Assembly
1 - ADJUSTER MECHANISM
2 - CLUTCH CABLE
Fig. 4 Clutch Release Lever and Bearing
1 - LEVER
2 - BEARING
6 - 2
CLUTCH
JR
CLUTCH (Continued)
SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASE
Oil leak at engine rear main or
transaxle input shaft seal.
Correct leak and replace modular clutch
assembly.
Too much grease applied to splines
of disc and input shaft.
Apply lighter coating of grease to splines.
NO FAULT FOUND WITH
CLUTCH
COMPONENTS
Problem actually related to
suspension or driveline component.
Further diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems.
Check EFI and ignition systems.
PARTIAL ENGAGEMENT
OF CLUTCH DISC
Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
Replace modular clutch assembly.
Clutch disc damaged or distorted.
Replace modular clutch assembly.
Clutch misalignment.
Verify modular clutch pilot plate alignment
to crankshaft. Replace the modular clutch
assembly if the pilot plate is loose or bent.
SERVICE DIAGNOSIS - CLUTCH SLIPS
CONDITION
POSSIBLE CAUSES
CORRECTION
DISC FACING WORN OUT
Normal wear.
Replace modular clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.
Replace modular clutch assembly.
Insufficient clutch cover diaphragm
spring tension
Replace modular clutch assembly.
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE
Leak at rear main oil seal or
transaxle input shaft seal
Replace leaking seals. Replace modular
clutch assembly.
Excessive amount of grease applied
to input shaft splines
Remove excessive grease from input shaft.
Replace modular clutch assembly
Road splash, water entering housing
Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY DISENGAGED
Release bearing sticking or binding,
does not return to normal running
position.
Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.
Cable self-adjuster mechanism
sticking or binding causing high
preload (2.0L Models).
Verify that self-adjuster is free to move.
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
Leak at rear main or transaxle input
shaft seal
Replace seal. Replace modular clutch
assembly.
Excessive heat from slippage
Replace modular clutch assembly
JR
CLUTCH
6 - 3
CLUTCH (Continued)
SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINES
Clutch disc hub splines damaged
during installation
Clean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly,
or clutch disc, and/or input shaft if splines
are severely damaged.
Input shaft splines rough, damaged.
Clean input shaft splines. Then lube.
Corrosion or rust formations on
splines of input shaft and disc
Clean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE
Occurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.
Replace modular clutch assembly
CLUTCH WILL NOT
DISENGAGE PROPERLY
Disc bent, distorted during transaxle
installation
Replace modular clutch assembly
Clutch cover diaphragm spring
damaged during transaxle installation
Replace modular clutch assembly
Release fork bent, loose, or
damaged
Replace fork if worn or damaged
Clutch cable binding or routed
incorrectly (2.0L Models).
Check and correct cable routing.
Self-adjuster in cable not functioning
properly, resulting in excess cable
slack (2.0L Models).
Pull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation.
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR
Pedal bushings worn out or
inadequate lubrication
Replace or lubricate bushings
Clutch pedal return spring worn out
Lubricate or replace return spring
CLUTCH PEDAL
SQUEAKS DURING
OPERATION
Clutch release lever pivot stud has
inadequate lubrication
Lubricate or replace clutch release lever
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
• Heat warping
• Mounting drive plate on a dirty crankshaft
flange
• Incorrect bolt tightening
• Improper seating on the crankshaft shoulder
• Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
6 - 4
CLUTCH
JR
CLUTCH (Continued)
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