Chrysler Stratus Convertible. Manual — part 212
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
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
Check and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable
slack
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 MAKES
REPEATED “POP” NOISE
IN THE FIRST INCH OF
TRAVEL
Self-adjusting mechanism in cable
defective
Replace clutch cable
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR
Pedal bushings worn out or
inadequate lubrication
Replace or lubricate bushings
Clutch pedal return spring worn out
Replace return spring
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.
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.
JX
CLUTCH
6 - 5
DIAGNOSIS AND TESTING (Continued)
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(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. If
chatter persists:
(2) Check to see if clutch cable routing is correct
and operates smoothly.
(3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary.
CLASH–INTO–REVERSE COMPLAINTS
All JA NV T350 (A-578) manual transaxles are
equipped with a reverse brake. It prevents clash
when shifting into reverse, but only if the vehicle is
not moving. See Group 21, Transaxle for further
diagnosis.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.
(2) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(3) Check the input shaft spline, clutch disc
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check
for
broken
clutch
cover
diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Pull up and remove Power Distribution Center.
(2) Remove clutch cable inspection cover.
(3) Pull back on clutch cable housing and disen-
gage cable from housing (Fig. 5).
(4) Guide cable through slot in transaxle and dis-
connect cable from release lever.
(5) Disconnect clutch cable up-stop/spacer with
cable strand from clutch pedal (Fig. 6).
NOTE: Depressing
the
clutch
pedal
provides
access to the clutch cable strand. Disconnect the
cable up-stop/spacer from the pedal pivot pin by
removing the retaining clip at the top of the clutch
pedal. Wedge a flat–blade pry tool between the pin
and the retaining tab. While holding the tab slightly
separated from the pin, pull the upstop/spacer off
the pedal. Now remove the cable end from the
upstop/spacer.
CAUTION: Do not pull on the clutch cable to
remove it from the dash panel. Damage to the cable
self-adjuster may occur.
(6) Use a slight twisting motion while grasping the
grommet and body to remove the cable from the dash
panel and clutch bracket.
Fig. 5 Cable at Transaxle
1 – BELLHOUSING
2 – CLUTCH CABLE
6 - 6
CLUTCH
JX
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
(1) Using a slight twisting motion, insert the self–
adjuster mechanism end of the clutch cable through
the dash panel hole and into the bracket.
(2) Seat the cylindrical part of the cable grommet
in the dash panel. Be sure the self–adjuster is firmly
seated against the clutch bracket to ensure proper
adjuster mechanism function.
(3) Connect the clutch cable to the up-stop/spacer.
(4) Connect the up-stop/spacer to the clutch pedal.
(5) Perform the Adjuster Mechanism Function
Check before finishing installation.
ADJUSTER MECHANISM FUNCTION CHECK
(1) With slight pressure, pull the clutch release
lever end of the cable to draw the cable taut. Push
the clutch cable housing toward the dash panel (With
less than 25 lbs. of effort, the cable housing should
move 30-50mm.). This indicates proper adjuster
mechanism function. If the cable does not adjust,
determine if the mechanism is properly seated on the
bracket.
(2) If the adjust mechanism functions properly,
guide the cable through the slot in the transaxle
housing. Connect cable to release lever, seating the
cupped washer securely on lever tangs.
(3) Pull back on clutch cable housing and insert
into transaxle housing (Fig. 5).
(4) Reinstall cable inspection cover and PDC.
Check clutch pedal position switch operation.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 7).
REMOVAL
(1) Disconnect electrical harness to switch connec-
tor.
(2) Depress wing tabs on switch and push switch
out of mounting bracket. Then slide wires through
slot in bracket.
INSTALLATION
(1) Slide switch wires through slot in switch
bracket.
(2) Line up switch tab with slot in switch bracket
and push switch into position. Do not pull on the
switch wires to seat switch into bracket, switch dam-
age may occur.
(3) Attach switch wiring harness to vehicle wiring
harness.
(4) After installation, the switch must be checked
for proper operation. Refer to Diagnosis and Testing
section for proper testing procedures.
Fig. 6 Cable End Removal
1 – CLUTCH PEDAL PIVOT PIN
2 – CABLE END
3 – UPSTOP/SPACER
4 – CLUTCH PEDAL
5 – CLUTCH CABLE
Fig. 7 Clutch Pedal Position Switch and
Components
1 – UPSTOP/SPACER
2 – CLUTCH PEDAL POSITION SWITCH
3 – CLUTCH PEDAL
4 – CLUTCH PEDAL RETURN SPRING
5 – CLUTCH CABLE
JX
CLUTCH
6 - 7
REMOVAL AND INSTALLATION (Continued)
CLUTCH ASSEMBLY
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(2) The transaxle and modular clutch come out as
an assembly.
(3) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 8). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.
NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
RELEASE BEARING AND FORK
Remove the transaxle from the vehicle. See Group
21, Transaxle for removal and installation proce-
dures.
REMOVAL
(1) Move the lever and bearing assembly to a ver-
tical in-line position. Grasp the release lever with
two hands in the pivot stud socket area. Pull with
even pressure and the lever will pop off the pivot–
stud. Do not use a screwdriver or pry bar to pop off
the lever. This may damage the spring clip on the
lever.
(2) As a unit, remove the fork from the bearing
thrust plate. Be careful not to damage retention tabs
on bearing.
(3) Examine the condition of the bearing. It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(4) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(5) Check the condition of the pivot stud spring
clips on back side of clutch fork. If the clips are bro-
ken or distorted, replace the clutch fork.
INSTALLATION
(1) The pivot ball pocket in the fork is Teflon
coated and should be installed WITHOUT any lubri-
cant such as grease. Using grease will break down
the Teflon coating. Be sure the ball stud and fork
pocket are clean of contamination and dirt.
(2) Assemble the fork to the bearing. The small
pegs on the bearing must go over the fork arms.
(3) Slide the bearing and fork assembly onto the
input shaft bearing retainer, as a unit.
(4) Snap the clutch fork onto the pivot ball.
(5) Reinstall transaxle assembly. Refer to Group
21, Transaxle for further information.
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
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.
Fig. 8 Clutch Components
1 – ENGINE
2 – UPPER COVER BOLT
3 – DRIVE PLATE TO CLUTCH BOLT
4 – CRANKSHAFT TO DRIVE PLATE BOLT BACKING PLATE
5 – DRIVE PLATE BOLT
6 – TRANSAXLE
7 – CLUTCH ASSEMBLY
8 – DRIVE PLATE
9 – TRANSAXLE CASE UPPER COVER
6 - 8
CLUTCH
JX
REMOVAL AND INSTALLATION (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст