Chrysler RG Voyager. Manual — part 455
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 (2.4L Gas) or clutch cover and
disc (2.5L TD).
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 (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch disc damaged or distorted.
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch misalignment.
Verify modular clutch pilot plate alignment
to crankshaft. Replace the modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD) if the pilot plate is loose or
bent.
Improper transaxle-to-engine
installation.
Verify transaxle is properly installed to
engine.
SERVICE DIAGNOSIS - CLUTCH SLIPS
CONDITION
POSSIBLE CAUSES
CORRECTION
DISC FACING WORN OUT
Normal wear.
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Insufficient clutch cover diaphragm
spring tension
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
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 (2.4L Gas) or clutch cover
and disc (2.5L TD).
Excessive amount of grease applied
to input shaft splines
Apply less grease to input shaft. Replace
modular clutch assembly (2.4L Gas) or
clutch cover and disc (2.5L TD).
Road splash, water entering housing
Seal housing. Inspect clutch assembly.
6a - 4
CLUTCH
RG
CLUTCH (Continued)
CONDITION
POSSIBLE CAUSES
CORRECTION
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.
Clutch pedal not returning to static
position.
Inspect pedal assembly for damage and/or
obstructions. Replace componnents as
necessary.
Clutch master cylinder or pushrod
damaged causing high preload.
Replace clutch master cylinder assembly.
Slave cylinder binding or stuck.
Replace slave cylinder.
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
Leak at rear main or transaxle input
shaft seal
Replace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD)..
Excessive heat from slippage
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
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 (2.4L
Gas) or clutch cover and disc (2.5L TD).
CLUTCH WILL NOT
DISENGAGE PROPERLY
Disc bent, distorted during transaxle
installation
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch cover diaphragm spring
damaged during transaxle installation
Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Release fork bent, loose, or
damaged
Replace fork if worn or damaged
Air in clutch hydraulic circuit.
Allow system to self-bleed or replace
hydraulic components.
Leak in clutch hydraulic circuit.
Replace worn/damaged/leaking hydraulic
components.
Clutch pedal requires
excessive force (high
release load).
Clutch disc is worn.
Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models).
RG
CLUTCH
6a - 5
CLUTCH (Continued)
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 at clutch
pedal pivot or master cylinder pushrod.
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 installation.
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 fingers.
DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly.
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky
or binding. Replace bearing, if needed.
(c) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(d) Check clutch assembly for contamination
(dirt, oil). Replace clutch assembly, if required.
(e) Check to see if the clutch disc hub splines
are damaged. Replace with new clutch assembly, if
necessary.
(f) Check
input
shaft
splines
for
damage.
Replace, if necessary.
(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly,
if necessary.
SPECIAL TOOLS - T850 TRANSAXLE
Disconnect Tool, 6638A
Remover/Installer, 6891
6a - 6
CLUTCH
RG
CLUTCH (Continued)
CLUTCH RELEASE LEVER AND
BEARING
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (2.4L Gas models only).
(3) Grasp clutch release lever and bearing (Fig. 6)
with both hands and pull outward using moderate
pressure to release lever from pivot ball.
(4) Separate release bearing from lever.
NOTE: Remove release lever pivot ball(s) ONLY if
replacement is necessary.
(5) Remove
pivot
ball(s)
using
slide
hammer
C-3752 and remover/installer 6891 (Fig. 7).
INSTALLATION
(1) If removed, install new release lever pivot
ball(s) using slide hammer C-3752 and remover/in-
staller 6891 (Fig. 8) (Fig. 9).
Fig. 6 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 7 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 8 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
RG
CLUTCH
6a - 7
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