Dodge Ram Truck 1500-2500-3500. Manual — part 218
CONDITION
POSSIBLE CAUSES
CORRECTION
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install a new bearing.
2. Bearing defective.
2. Install a new bearing.
3. Bearing not lubricated.
3. Install a new bearing.
4. Clutch misalignment.
4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly.
1. Low hydraulic linkage fluid level.
1. Add hydraulic linkage fluid.
2. Clutch cover loose.
2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted.
3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards.
5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
Clutch pedal squeak.
1. Pivot pin loose.
1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
4. Rough surface on front bearing
retainer.
4. Replace front bearing retainer.
Clutch master or slave cylinder
plunger dragging andør binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy.
1. Release bearing defective or
damaged.
1. Replace release bearing.
6 - 4
CLUTCH
DR/DH
CONDITION
POSSIBLE CAUSES
CORRECTION
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned.
3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment.
4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Slave Cylinder Nuts
23
17
-
Clutch Master Cylinder
Nuts
28
21
-
Pressure Plate Bolts - V6
& V8
50
37
-
Pressure Plate Bolts - V10
30
22.5
-
Pressure Plate Bolts -
Diesel
30
22.5
-
Release Bearing Pivot
23
17
-
Flywheel Bolts
95
70
-
Dual Mass Flywheel To
Adapter Bolts
55
40
-
Dual Mass Flywheel
Adapter To Crankshaft
Bolts
137
100
-
DR/DH
CLUTCH
6 - 5
SPECIAL TOOLS
LINE DISCONNECT TOOL 6638
6 - 6
CLUTCH
DR/DH
DISC CLUTCH
REMOVAL
1. Support engine with wood block and adjustable
jack stand, to prevent strain on engine mounts.
2. Remove
transmission
and
transfer
case,
if
equipped.
3. If pressure plate (3) will be reused, mark (2) the
position on flywheel (1) with paint or scriber. Also
note location marks on the pressure next to the
bolt holes. The mark will be a L or a circle with an
X in it.
4. Insert clutch alignment tool through clutch disc and
into pilot bushing, to hold disc in place while
removing bolts.
5. Loosen pressure plate bolts evenly, a few threads
at a time and in a diagonal pattern to prevent warp-
ing the plate.
6. Remove bolts completely and remove pressure
plate, disc and alignment tool.
INSTALLATION
1. Check runout and free operation of new clutch
disc.
2. Lubricate crankshaft pilot bearing with a NLGI - 2
rated grease.
3. Install clutch alignment tool in clutch disc hub with
the raised side of hub is facing away from the fly-
wheel.
NOTE: Flywheel side is imprinted on the disc face.
4. Install alignment tool (3) in pilot bearing and posi-
tion disc on the flywheel (1).
5. Position pressure plate over disc (2) and onto the
flywheel.
6. Align and hold pressure plate in position and install
bolts finger tight.
7. Tighten bolts evenly and a few threads at a time in a diagonal pattern.
CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover.
8. Tighten pressure plate bolts to:
•
V6 & V8 Engines - 50 N·m (37 ft. lbs.)
•
V10 & Diesel Engines - 30 N·m (22.5 ft. lbs.)
DR/DH
CLUTCH
6 - 7
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