Dodge Nitro. Manual — part 496

Fig. 754: Body In White Complete (3 Of 4)
Courtesy of CHRYSLER LLC

Fig. 755: Body In White Complete (4 Of 4)
Courtesy of CHRYSLER LLC

2007 Dodge Nitro R/T

2007 ACCESSORIES AND EQUIPMENT Body - Nitro

2007 CLUTCH

Clutch - Nitro

WARNING

CLUTCH

DIAGNOSIS AND TESTING

CLUTCH

Drive the vehicle at normal speeds. Shift the transmission through all gear ranges and observe clutch action. If
the clutch chatters, grabs, slips or does not release properly, remove and inspect the clutch components. If the
problem is noise or hard shifting, further diagnosis may be needed as the transmission or another driveline
component may be at fault.

CLUTCH CONTAMINATION

Fluid contamination is a frequent cause of clutch malfunctions. Oil, water or clutch fluid on the clutch disc and
pressure plate surfaces will cause chatter, slip and grab. Inspect components for oil, hydraulic fluid or
water/road splash contamination.

Oil contamination indicates a leak at either the rear main seal or transmission input shaft. Clutch fluid leaks are
usually from damaged slave cylinder push rod seals. Heat buildup caused by slippage between the pressure
plate, disc and flywheel can bake the oil residue onto the components. The glaze-like residue ranges in color
from amber to black.

Road splash contamination is dirt/water entering the clutch housing due to loose bolts, housing cracks. Driving
through deep water puddles can force water/road splash into the housing through such openings.

IMPROPER RELEASE OR CLUTCH ENGAGEMENT

WARNING:

DaimlerChrysler does not manufacture any vehicles that utilize asbestos
containing products. Manual clutches on older model vehicles and
aftermarket manual clutch facings may contain asbestos. Refer to
aftermarket product packaging for product information. Regardless if the
product contains asbestos or not, dust and dirt can accumulate on
manual clutch parts during normal use. Follow all recommended safety
practices prescribed by the occupational safety and health administration
(OSHA) and the environmental safety agency (EPA), for the handling and
disposal of products containing asbestos. Failure to follow these
instructions may result in personal injury

NOTE:

Vehicles equipped with a Dual Mass Flywheel may produce a rattle when the
engine is shut off. This noise is considered normal.

2007 Dodge Nitro R/T

2007 CLUTCH Clutch - Nitro

2007 Dodge Nitro R/T

2007 CLUTCH Clutch - Nitro

Clutch release or engagement problems are caused by wear or damage clutch components. A visual inspection
of the release components will usually reveal the problem part.

Release problems can result in hard shifting and noise. Look for leaks at the clutch cylinders and
interconnecting line and loose slave cylinder bolts. Also worn/loose release fork, pivot stud, clutch disc,
pressure plate or release bearing.

Engagement problems can result in slip, chatter/shudder and noisy operation. The causes may be clutch disc
contamination, wear, distortion or flywheel damage. Visually inspect to determine the actual cause of the
problem.

CLUTCH MISALIGNMENT

Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment
caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch
release.

PRESSURE PLATE AND DISC RUNOUT

Check the clutch disc before installation. Axial (face) runout of a new disc should not exceed 0.50 mm (0.020
in.). Measure runout about 6 mm (1/4 in.) from the outer edge of the disc facing. Obtain another disc if runout is
excessive.

Check condition of the clutch before installation. A warped cover or diaphragm spring will cause grab and
incomplete release or engagement. Be careful when handling the cover and disc. Impact can distort the cover,
diaphragm spring, release fingers and the hub of the clutch disc.

Use an alignment tool when positioning the disc on the flywheel. The tool prevents accidental misalignment
which could result in cover distortion and disc damage.

A frequent cause of clutch cover distortion (and consequent misalignment) is improper bolt tightening.

FLYWHEEL RUNOUT

Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm
(0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a
stud installed in place of one of the flywheel bolts.

Common causes of runout are:

Heat warpage

Improper machining

Incorrect bolt tightening

Improper seating on crankshaft flange shoulder

Foreign material on crankshaft flange

2007 Dodge Nitro R/T

2007 CLUTCH Clutch - Nitro

Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and
machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or
with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003
in.). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than
0.076 mm (0.003 in.). Excessive stock removal can result in flywheel cracking or warpage after installation; it
can also weaken the flywheel and interfere with proper clutch release.

Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the
flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with
Mopar® Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can
distort the flywheel hub causing runout.

DIAGNOSIS CHART

The Diagnosis Chart describes common clutch problems, causes and correction. Conditions, causes and
corrective action are outlined in the indicated columns.

DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSES

CORRECTION

Disc facing worn out

1. Normal wear.

1. Replace cover and disc.

2. Driver frequently rides (slips)
the clutch. Results in rapid
overheating and wear.

2. Replace cover and disc.

3. Insufficient clutch cover
diaphragm spring tension.

3. Replace cover and disc.

Clutch disc facing contaminated
with oil, grease, or clutch fluid.

1. Leak at rear main engine seal or
transmission input shaft seal.

1. Replace appropriate seal.

2. Excessive amount of grease
applied to the input shaft splines.

2. Remove grease and apply the
correct amount of grease.

3. Road splash, water entering
housing.

3. Replace clutch disc. Clean
clutch cover and reuse if in good
condition.

4. Slave cylinder leaking.

4. Replace hydraulic clutch
linkage.

Clutch is running partially
disengaged.

1. Release bearing sticking or
binding and does not return to the
normal running position.

1. Verify failure. Replace the
release bearing and transmission
front bearing retainer as necessary.

Flywheel below minimum
thickness specification.

1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.

1. Replace flywheel.

Clutch disc, cover and/or
diaphragm spring warped or
distorted.

1. Rough handling. Impact bent
cover, spring, or disc.

1. Replace disc or cover as
necessary.

2. Improper bolt tightening
procedure.

2. Tighten clutch cover using
proper procedure.

Facing on flywheel side of disc
torn, gouged, or worn.

1. Flywheel surface scored or
nicked.

1. Correct surface condition if
possible. Replace flywheel and

2007 Dodge Nitro R/T

2007 CLUTCH Clutch - Nitro