Dodge Ram Truck 1500-2500-3500. Manual — part 220

9. Subtract each reading from the one 180° opposite

to determine runout and direction. Bore runout
example:

•

0.000 – (–0.007) = 0.007 in.

•

+0.002 – (–0.010) = 0.012 in.

•

+0.004 – (–0.005) = 0.009 in.

•

–0.001 – (+0.001) = –0.002 in.

In this example the largest or total indicator reading
(TIR) difference is 0.012 inch. This means the housing
bore is offset from the crankshaft centerline by 0.006
in. which is 1/2 of 0.012 inch. The dowels (2) needed
to correct this have an offset of 0.007 in.

Remove housing and install dowels with the slotted
side facing out so they can be turned with a screw-
driver. Then install the housing and mount the dial
indicator and check bore runout again. Rotate the dowels until the TIR is less than 0.010 inch.

Clutch Housing Face Runout

1. Position dial indicator (2) towards the housing face

with indicator plunger (1) on the rim of the housing
bore.

2. Rotate crankshaft until indicator plunger is at the

10 O’clock position and zero the dial indicator.

3. Measure and record face runout (1) readings at

four points 90° apart. Take measurement at least
twice for accuracy.

4. Subtract lowest reading from highest to determine

total runout. If low reading was minus 0.004 in.
and highest reading was plus 0.009 in. the total
runout is 0.013 inch.

NOTE: Maximum acceptable face runout is 0.010
inch.

To correct this example the shims needed between
the clutch housing and transmission are:

•

0.009 in. at the 0.000 corner

•

0.012 in. at the –0.003 corner

•

0.013 in. at the –0.004 corner

After installing the clutch assembly and housing, tighten the housing bolts nearest the alignment dowels first.

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CLUTCH

DR/DH

NOTE: Shims can be made from shim stock or
similar materials of the required thickness.

REMOVAL

1. Remove transmission (2) and transfer case.

2. Remove starter from clutch housing.

3. Remove structural dust cover bolts from clutch

housing.

CAUTION: Do not remove structural dust cover
from enigne block. If cover is removed clutch
housing and cover must be aligned with the
engine.

4. Remove clutch housing (1) bolts and remove hous-

ing from the engine.

DR/DH

CLUTCH

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INSTALLATION

1. Clean housing mounting surface of engine block

(1) with wax and grease remover.

2. Verify that clutch housing alignment dowels are in

good condition and properly seated.

3. Transfer slave cylinder, release fork and boot, fork

pivot stud and wire/hose brackets to new housing
(3).

4. Install structural dust cover (4) if removed (Refer to

9

-

ENGINE/ENGINE

BLOCK/STRUCTURAL

COVER - INSTALLATION).

5. Align and install clutch housing (3) on engine (1).

Tighten housing bolts across the top of the housing
first and to the following torque values:

•

“A” bolts 1/4in. diameter - 4.5 N·m (40 in.lb.)

•

“A” bolts 3/8in. diameter - 40 N·m (30 ft.lb.)

•

“A” bolts 7/16in. diameter - 68 N·m (50 ft.lb.)

•

“B” bolts for 5.7L 5.9L TD/8.0L engines - 47.5
N·m (40 ft.lb.)

•

“C” bolts for 5.7L engine - 68 N·m (50 ft.lb.)

•

“C” bolts for 5.9L TD engine - 47.5 N·m (35 ft.lb.)

•

“C” bolts for 8.0L engine - 74.5 N·m (55 ft.lb.)

6. Install starter to clutch housing.

7. Install transmission and transfer case, if equipped.

BEARING CLUTCH RELEASE

REMOVAL

1. Remove

transmission

and

transfer

case,

if

equipped.

2. Remove spring clip (6).

3. Disconnect release bearing (4) from release lever

(3) and remove bearing.

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CLUTCH

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INSTALLATION

1. Inspect bearing slide surface on transmission front

bearing retainer. Replace retainer if slide surface is
scored, worn, or cracked.

2. Inspect release lever and pivot stud (1). Verify stud

is secure and in good condition and lever is not
distorted or worn. Replace fork spring clips if bent
or damaged.

3. Lubricate input shaft splines, bearing retainer slide

surface, lever pivot ball stud (1), and release lever
pivot surface with Mopar

T

high temperature bearing

grease.

4. Install release fork and release bearing. Verify fork

and bearing are properly secured by spring clips
and release lever is installed properly. Rear side of
release lever has one end with a raised area,
which goes toward the slave cylinder side of the
transmission.

5. Install clutch housing, if removed.

6. Install transmission and transfer case.

BEARING CLUTCH RELEASE - SRT-10

REMOVAL

NOTE: The bearing and slave cylinder are serviced
together as an assembly. Do not attempt to sepa-
rate the bearing from the slave cylinder.

1. With vehicle in neutral, position vehicle on hoist.

2. Disconnect hydraulic line from hydraulic slave cyl-

inder with Line Disconnect Tool 6638/6638A.

3. Remove transmission.

4. Remove slave cylinder (1) bolts and remove

cylinder.

DR/DH

CLUTCH

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