Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 177
TIGHTENING REFERENCE
.
ANTI-LOCK BRAKES
5 - 91
MANUAL TRANSAXLE CLUTCH
CONTENTS
page
page
CLEANING PRECAUTIONS
. . . . . . . . . . . . . . . . . 9
CLUTCH DISC REPLACEMENT
. . . . . . . . . . . . . . 8
CLUTCH CABLE REPLACEMENT
. . . . . . . . . . . . 5
CLUTCH CABLE MECHANISM
. . . . . . . . . . . . . . 1
CLUTCH CHATTER COMPLAINTS . . . . . . . . . . . . 1
CLUTCH/STARTER INTERLOCK SWITCH
. . . . . . 7
EXCESSIVE CLUTCH SPIN TIME/CLASH
INTO REVERSE COMPLAINTS . . . . . . . . . . . . . 1
GENERAL INFORMATION
. . . . . . . . . . . . . . . . . . 1
RELEASE BEARING AND FORK
. . . . . . . . . . . . . 9
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of this
service manual.
The clutch used in all models is a single, dry disc type
with automatic adjustment for wear being provided in
the clutch pedal.
The clutch pedal is connected to the torque shaft
through a cable and lever.
The upper end of the clutch pedal pivots in the pedal
bracket on two nylon bushings. These bushings do not
require periodic lubrication.
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
complaint has 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 bushings.
Replace all worn parts.
(7) Check flywheel and clutch pressure plate for
contamination (dirt, oil) or scored. Replace flywheel
and/or pressure plate, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new disc.
(9) Check input shaft on the transaxle for damaged
splines. Replace if necessary.
(10) Check for uneven wear on clutch fingers.
EXCESSIVE CLUTCH SPIN TIME/CLASH INTO RE-
VERSE COMPLAINTS
For all excessive clutch spin time/clash into reverse
complaints, do the following:
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time.
(2) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(3) Check the input shaft spline, clutch disc spline
and release bearing for dry rust. If dry rust is present,
clean rust off. Apply a light coat of bearing grease to
the input shaft spline, where the clutch disc slides.
(4) Check to see if the clutch disc hub splines are
damaged. If damaged replace with new disc.
(5) Check input shaft spline of the transaxle for
damage. Replace input shaft if required.
(6) Install clutch assembly and transaxle.
CLUTCH CABLE MECHANISM
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear. This adjuster mechanism is located
within the clutch pedal. The preload spring maintains
tension on the cable. This tension keeps the clutch
release bearing continuously loaded against the fingers
of the clutch cover assembly.
When the pedal is depressed, teeth on the adjuster
and the positioner engage and pull the release cable. A
spring located behind the adjuster ensures proper
tooth engagement.
When the pedal is released, the adjuster contacts the
bumper. This separates the adjuster and positioner
teeth,
allowing
the
preload
spring
to
function.
.
MANUAL TRANSAXLE CLUTCH
6 - 1
SERVICE DIAGNOSIS—CLUTCH SLIPS
6 - 2
MANUAL TRANSAXLE CLUTCH
.
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