Chrysler Town, Dodge Caravan. Manual — part 62
Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines
1 - FLYWHEEL
2 - DISC
3 - PRESSURE PLATE
6 - 2
CLUTCH
RS
CLUTCH (Continued)
RELEASE SYSTEM
All models utilize a hydraulic clutch release sys-
tem, conisting of a clutch master cylinder attached to
the clutch pedal (Fig. 3), and a slave cylinder fas-
tened to the transaxle which operates the clutch
release lever (Fig. 4). When the driver depresses the
clutch pedal, the master cylinder pushrod travels
through the cylinder bore, displacing fluid through
the master cylinder plumbing. This fluid displace-
ment forces the slave cylinder piston to travel, forc-
ing the clutch release bearing into the clutch
diaphragm spring via the release lever and leverage
(Fig. 5). This releases the clamping force on the
clutch disc, allowing the engine crankshaft to rotate
independently from the transaxle input shaft.
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. 3 Clutch Master Cylinder - Typical
1 - CLUTCH PEDAL
2 - BUSHING
3 - GROMMET
4 - MASTER CYLINDER
5 - STOP
Fig. 4 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
Fig. 5 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
RS
CLUTCH
6 - 3
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 (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.
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.
6 - 4
CLUTCH
RS
CLUTCH (Continued)
CONDITION
POSSIBLE CAUSES
CORRECTION
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).
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
RS
CLUTCH
6 - 5
CLUTCH (Continued)
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