Dodge Caliber. Manual — part 161
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.
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.
T355 equipped- Correct leak and replace
modular clutch assembly.
BG6 equipped - Clean pressure plate,
flywheel, and replace clutch disc.
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 clutch assembly.
Clutch disc damaged or distorted.
Replace clutch assembly.
Clutch misalignment.
T355 equipped - Verify modular clutch pilot
plate alignment to crankshaft. Replace the
modular clutch assembly if the pilot plate is
loose or bent.
BG6 equipped - Check alignment and
runout of flywheel, disc, or cover. Check
clutch housing to engine dowels and dowel
holes for damage. Correct as necessary.
CLUTCH SLIPS
CONDITION
POSSIBLE CAUSES
CORRECTION
DISC FACING WORN OUT
Normal wear.
Replace clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.
Replace clutch assembly.
Insufficient clutch cover diaphragm
spring tension
Replace clutch assembly.
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE
Leak at rear main oil seal or
transaxle input shaft seal
T355 equipped - Replace leaking seals.
Replace clutch assembly.
BG6 equipped - Replace leaking seals.
Clean the pressure plate and flywheel
surface and replace clutch disc.
PM
CLUTCH
6 - 3
CONDITION
POSSIBLE CAUSES
CORRECTION
Excessive amount of grease applied
to input shaft splines
T355 equipped - Apply less grease to input
shaft. Replace clutch assembly.
BG6 equipped - Apply less grease to input
shaft. Clean the pressure plate and flywheel
surface and replace clutch disc.
Road splash, water entering housing
Seal housing. Inspect clutch assembly.
Concentric Slave Cylinder leaking
hydraulic fluid
Replace Concentric Slave Cylinder (CSC)
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 master cylinder pushrod not
adjusted properly (LHD Models),
causing high preload.
Verify that pushrod adjustment is correct
(LHD Models).
Slave cylinder binding
Replace slave cylinder
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
Driver performs a 5-1 downshift at
vehicle speed in excess of 60 miles
per hour
Alert driver to problem cause. Replace
clutch assembly. Inspect slave cylinder,
fork, and bearing for damage.
Leak at rear main or transaxle input
shaft seal
T355 equipped - Replace seal. Replace
clutch assembly.
BG6 equipped - Replace seal. Clean the
pressure plate and flywheel surface and
replace clutch disc.
Excessive heat from slippage
Replace Clutch Assembly
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 clutch assembly.
CLUTCH WILL NOT
DISENGAGE PROPERLY
Disc bent, distorted during transaxle
installation
Replace clutch assembly.
Clutch cover diaphragm spring
damaged during transaxle installation
Replace clutch assembly.
Release lever bent, loose, or
damaged
Replace release lever if worn or damaged
Air in clutch hydraulic system.
Bleed clutch hydraulic system to purge air.
Clutch master cylinder or slave
cylinder leaking
Check and replace master and/or slave
cylinder
6 - 4
CLUTCH
PM
CONDITION
POSSIBLE CAUSES
CORRECTION
Master cylinder adjustable pushrod
loose or damaged
Inspect. Tighten adjustment fastener or
replace master cylinder.
Pushrod not retained to clutch pedal
pin.
Inspect pushrod & bushing. Replace as
necessary.
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
Clutch pedal return spring worn out
Lubricate or replace return spring
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, perform 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.
2. If chatter persists, check hydraulic clutch release system is functioning properly.
3. Check for loose connections in drivetrain. Correct any problems and determine if clutch chatter complaints have
been satisfied. If not:
a. Remove transaxle.
b. Check to see if the release bearing is sticky or binding. Replace bearing, if needed.
c. Check clutch assembly for contamination (dirt, oil). Replace clutch assembly, if required.
d. Check to see if the clutch disc hub splines are damaged. Replace with new clutch assembly, if necessary.
e. Check input shaft splines for damage. Replace, if necessary.
f. Check for uneven wear on clutch fingers.
g. Check for broken clutch cover diaphragm spring fingers. Replace with new clutch assembly, if necessary.
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-
ment the flywheel, causing excessive runout. Use new bolts when mounting drive plate to crankshaft. Tighten drive
plate bolts to specified torque only. Over-tightening can distort the drive plate hub causing excessive runout.
CLASH-INTO-REVERSE COMPLAINTS
All T355 manual transaxles are equipped with a reverse brake. It prevents clash when shifting into reverse, but only
if the vehicle is not moving.
1. Depress clutch pedal to floor and hold. After three seconds, shift to reverse. If clash is present, clutch has exces-
sive spin time, and the reverse brake may not be functioning.
2. Remove transaxle.
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.
PM
CLUTCH
6 - 5
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.
STANDARD PROCEDURE
GRAVITY BLEEDING CLUTCH HYDRAULIC CIRCUIT
1. Verify fluid level in brake master cylinder. Top off
with DOT 3 brake fluid as necessary. Leave cap
off.
2. Raise vehicle on hoist.
3. Remove bleed port protective cap and install suit-
able size and length of clear hose (4) to monitor
and divert fluid into suitable container.
4. Open up the bleed circuit by turning the thumb
screw (3) counter clockwise this will start the air
purge and fluid fill process.
5. Lower vehicle, but only enough to gain access to
and fill the brake master cylinder.
NOTE: Do not allow clutch master cylinder to run
dry while fluid exits bleed port. If master cylinder
runs dry, it is necessary to remove clutch master
cylinder, position vertically (with push rod down)
for 10 seconds, and reinstall.
6. Top off brake master cylinder fluid level while air is
purged and fluid drains from bleed port. Continue
this until no air bubbles are seen and a solid column of fluid exists.
7. Close hydraulic bleed circuit, remove drain hose and replace dust cap on bleed port.
8. From driver’s seat, actuate clutch pedal 60-100 times.
9. Apply parking brake. Start engine and verify clutch operation and pedal feel. If pedal feels fine and clutch oper-
ates as designed, stop here. If pedal still feels spongy or clutch does not fully disengage, excessive air is still
trapped within the system, most likely at the master cylinder.
10. Top off brake master cylinder fluid level with DOT 3 brake fluid as necessary.
POWER BLEEDING CLUTCH HYDRAULIC CIRCUIT
1. Remove reservoir cap and connect bleeder cap to reservoir.
NOTE: Use Bleeder Cap/Modified reservoir cap adapter Snap-on #901-059 or equivalent
2. Connect service filling machine to bleeder cap.
NOTE: Use Service Filling Machine/Brake power bleeder Brake power bleeder or equivalent
3. Service filling machine should be pressurized to at least 2.5 bar (36 PSI).
4. Remove dust cap from bleeder valve and connect the transparent bleeder hose to bleeder valve.
5. Place the other end of hose in the bleeder container to capture the used fluid. The end of the hose MUST be
submerged in the DOT 3 brake fluid.
NOTE: Use Bleeder Container To capture hydraulic fluid and Transparent Bleeder Hose To route fluid to
container
6. Turn on the service filling machine.
6 - 6
CLUTCH
PM
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