Dodge Dakota (R1). Manual — part 245
INSTALLATION
NOTE: The hydraulic linkage is serviced as a com-
plete assembly only. The individual components
must not be serviced separately.
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser-
voir in vehicle.
(3) Insert clutch master cylinder in dash panel.
(4) Position reservoir on dash panel and install
reservoir screws. Tighten screws to 5 N·m (40 in.
lbs.).
(5) Install nuts that hold clutch master cylinder to
dash panel. Tighten nuts to 54 N·m (40 ft. lbs.).
(6) Apply light coating of grease to the inner diam-
eter of the master cylinder push–rod and the outer
diameter of the clutch pedal pin.
(7) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with retaining clip.
(8) Connect clutch pedal position switch connector
from wiring harness.
(9) Raise vehicle.
(10) Insert slave cylinder push rod through clutch
housing opening and into release lever. Be sure end
of rod is securely engaged in release lever. Check this
before installing cylinder attaching nuts.
NOTE: If new clutch linkage is being installed, do
not remove plastic shipping strap from the slave
cylinder push rod. The strap will break on its own
upon first clutch application.
(11) Install and tighten slave cylinder attaching
nuts to 23 N·m (200 in. lbs.).
(12) Install hydraulic fluid line clip into the hole in
the lower dash panel flange.
Fig. 14 Clutch
1 - CLUTCH FLUID RESERVOIR
2 - CLUTCH PEDAL
3 - CLUTCH SAVE CYLINDER
4 - CLUTCH HYDRAULIC LINE
5 - CLUTCH PEDAL
6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR
7 - CLUTCH HYDRAULIC LINE
8 - CLUTCH MASTER CYLINDER
6 - 14
CLUTCH
AN
LINKAGE (Continued)
(13) Verify that fluid line from master cylinder to
slave cylinder is properly routed.
CLUTCH PEDAL
REMOVAL
(1) Remove retaining clip securing push rod on
clutch pedal (Fig. 16).
(2) Slide push rod off clutch pedal pin.
(3) Remove snap ring and washer attaching clutch
pedal to the pivot shaft.
(4) Slide pedal off pivot shaft and remove pedal.
(5) Remove and inspect bushings in pedal bore.
Replace bushings if worn or cracked.
INSTALLATION
(1) Lubricate pedal bushings and shaft with a sili-
cone grease or with Mopar
t multi-mileage grease.
(2) Install bushings in pedal bore and on pin.
(3) Install pedal on pivot shaft.
(4) Secure pedal on shaft with washer and snap
ring.
(5) Apply light coating of grease to the inner diam-
eter of the master cylinder push-rod and the outer
diameter of the clutch pedal pin.
(6) Connect push rod to pedal and secure rod with
retaining clip.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
A clutch pedal position switch is in the starter cir-
cuit. The switch is located on the clutch master cyl-
inder push rod.
Fig. 15 Clutch Hydraulic Linkage
1 - CLUTCH FLUID RESERVOIR
2 - CLUTCH PEDAL
3 - CLUTCH SAVE CYLINDER
4 - CLUTCH HYDRAULIC LINE
5 - CLUTCH PEDAL
6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR
7 - CLUTCH HYDRAULIC LINE
8 - CLUTCH MASTER CYLINDER
AN
CLUTCH
6 - 15
LINKAGE (Continued)
OPERATION
The switch, which is in circuit with the starter
solenoid, requires that the clutch pedal be fully
depressed in order to start the engine. Switch cir-
cuitry
and
operation
is
provided
in
section
8
Electrical.
Fig. 16 Clutch Pedal
1 - PIVOT ROD
2 - PEDAL SUPPORT
3 - BRAKE PEDAL
4 - BOOSTER ROD
5 - CLUTCH ROD
6 - CLUTCH PEDAL
6 - 16
CLUTCH
AN
CLUTCH PEDAL POSITION SWITCH (Continued)
CLUTCH
TABLE OF CONTENTS
page
page
CLUTCH
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
CLUTCH DISC
FLYWHEEL
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RING GEAR
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH
SPECIFICATIONS
SPECIFICATIONS - CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Clutch Bolts
50
37
-
Pilot Bearing Retainer Bolts
28
20
-
Clutch Housing to Trans Bolts
46
34
-
Clutch Housing to Engine Bolts
Top 2 Bolts
37
27
-
Middle 2 Bolts
58
43
-
Bottom 2 Bolts
75
55
-
CLUTCH DISC
REMOVAL
(1) Remove manual transmission. Refer to 21
Transmission and Transfer Case for procedure.
(2) If original clutch cover will be reused, mark
position of cover on flywheel for installation refer-
ence.
(3) Loosen cover bolts evenly in a star pattern to
relieve spring tension equally. This will prevent the
cover from warping.
NOTE: If clutch cover will be replaced, cover bolts
can be removed in any sequence.
(4) Remove cover and disc (Fig. 1).
INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth. Then clean surface with brake cleaner.
(2) Apply light coat of Mopar high temperature
bearing grease or equivalent to pilot bearing and
splines of transmission input shaft.
CAUTION: Do not over-lubricate as this will result in
grease contamination of the disc.
(3) Sliding disc onto transmission output shaft
splines. Disc should slide onto splines freely without
binding.
(4) Position clutch disc on flywheel with the side
marked “flywheel side” against flywheel (Fig. 2). If
disc is not marked the flat side of disc hub is placed
toward the flywheel.
R1
CLUTCH
6a - 1
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