Chrysler RG Voyager. Manual — part 678
INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45° clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45° counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder “quick connect” fitting. An audible
“click” should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8) Diesel models: Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove
clutch
master
cylinder
pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
Fig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RS
CLUTCH
6 - 9
MASTER CYLINDER - RHD (Continued)
(10) Using Tool 6638A, disconnect clutch master
cylinder “quick connect” fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove
master
cylinder
reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45° and removing from
dash panel (Fig. 18).
(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45° counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible “click” should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N·m (100 in. lbs.)
(Fig. 18).
(5) Install
windshield
wiper
module
assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10
CLUTCH
RS
MASTER CYLINDER - LHD (Continued)
MODULAR CLUTCH ASSY -
2.4L GAS
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (Fig. 19).
INSTALLATION
(1) Install modular clutch assembly to transaxle
input shaft (Fig. 19).
(2) Install transaxle to vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
SLAVE CYLINDER
REMOVAL
(1) Raise vehicle on hoist. Diesel models: Remove
underbody splash shield.
(2) Using Tool 6638A, disconnect hydraulic clutch
circuit quick connect fitting.
(3) Remove clutch slave cylinder (Fig. 20) by lifting
nylon tab with a small screwdriver, and then
depressing cylinder inward towards case and rotating
cylinder 60° counter-clockwise.
INSTALLATION
(1) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs. While depress-
ing inward, rotate slave cylinder clockwise until
nylon locating tab rests in transaxle case cutout, and
the hydraulic tube is vertical (Fig. 20).
(2) Connect “quick-connect” connection until an
audible “click” is heard. Verify connection by pulling
outward on connection.
(3) Diesel
models:
Install
underbody
splash
shield.
(4) Lower vehicle.
CLUTCH DISC AND PRESSURE
PLATE - 2.5L TD
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove six (6) clutch pressure plate-to-fly-
wheel bolts. Remove pressure plate and disc from fly-
wheel (Fig. 21).
(3) Inspect flywheel. Resurface/replace as necessary.
(4) Inspect
clutch
release
bearing
and
lever.
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
Fig. 19 Modular Clutch Assembly
1 - MODULAR CLUTCH ASSEMBLY
2 - INPUT SHAFT
Fig. 20 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
RS
CLUTCH
6 - 11
INSTALLATION
(1) Install clutch release bearing and lever (if
removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE
BEARING - INSTALLATION)
(2) Install clutch disc and pressure plate to fly-
wheel (Fig. 21). Install clutch alignment tool, and
install and torque pressure plate-to-flywheel bolts to
28 N·m (250 in. lbs.).
(3) Install transaxle assembly. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL - INSTALLATION)
FLYWHEEL
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove clutch pressure plate and disc. (Refer
to 6 - CLUTCH/CLUTCH DISC - REMOVAL)
(3) Remove flywheel assembly (Fig. 22).
INSTALLATION
(1) Install NEW flywheel-to-crankshaft bolts by
hand.
(2) Torque bolts in a criss-cross sequence to 25
N·m (18 ft. lbs.) (Fig. 22).
(3) Torque bolts in a criss-cross sequence an addi-
tional 60°.
(4) Install clutch pressure plate and disc. (Refer to
6 - CLUTCH/CLUTCH DISC - INSTALLATION)
(5) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
Fig. 21 Clutch Disc and Pressure Plate
1 - FLYWHEEL
2 - DISC
3 - PRESSURE PLATE
Fig. 22 Flywheel Bolt Torque Sequence
6 - 12
CLUTCH
RS
CLUTCH DISC AND PRESSURE PLATE - 2.5L TD (Continued)
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