Dodge Viper SRT-10 (ZB). Manual — part 47
CLUTCH DISC
REMOVAL
(1) Remove transmission.
(2) Remove clutch inspection cover 2 screws.
(3) Remove bell housing bolts (6). Remove bell
housing from engine (Fig. 7).
(4) Mark clutch cover (pressure plate) and flywheel
to maintain their same relative positions when rein-
stalling clutch assembly.
(5) Insert Clutch Disc Aligning Tool through the
clutch disc hub to prevent the clutch disc from falling
and damaging the facings.
(6) Loosen clutch cover (pressure plate) attaching
bolts, one or two turns at a time, in a crisscross pat-
tern. This will release spring pressure evenly and
avoid clutch cover damage.
(7) Remove
the
clutch
cover
(pressure
plate)
assembly and disc from flywheel. Handle carefully to
avoid contaminating the friction surfaces.
CLEANING
Clean flywheel face with crocus cloth or 400-600
grade sandpaper, then wipe the surface with mineral
spirits. If the surface is severely scored, heat checked
or warped, replace the flywheel.
CAUTION: Never machine the flywheel face. If fly-
wheel surface is bad the flywheel must be replaced.
Wipe the friction surface of the pressure plate with
mineral spirits.
INSTALLATION
NOTE: If the flywheel is to be replaced or removed
apply thread sealer to the flywheel retaining bolts
when installing. This will prevent engine oil from
leaking onto the clutch.
(1) Mount clutch assembly on flywheel (Fig. 8),
being careful to properly align dowels and the align-
ment marks made before removal. If new clutch or
flywheel is installed, align cover balance spot as close
as possible to flywheel balance orange spot. Apply
pressure to the alignment tool. Lightly tighten the
clutch cover bolts enough to hold the disc in position.
Fig. 7 CLUTCH BELLHOUSING
1 - CLUTCH DISC
2 - PRESSURE PLATE
3 - BELL HOUSING
Fig. 8 CLUTCH ASSEMBLY
1 - FLYWHEEL
2 - PRESSURE PLATE
6 - 8
CLUTCH
ZB
(2) To avoid distortion of the clutch cover (pressure
plate), tighten bolts a few turns at a time in
sequence (Fig. 9) until bolts are seated. Then tighten
bolts in sequence to 30 N·m (270 in. lbs.). Remove
clutch disc alignment tool.
(3) Install transmission into vehicle.
CLUTCH RELEASE BEARING
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) Raise vehicle on hoist.
(2) Disconnect hydraulic line from hydraulic slave
cylinder. Use the quick disconnect tool (special tool
6638) to open the coupling.
(3) Remove transmission assembly from the vehi-
cle.
(4) Remove slave cylinder (Fig. 10) from transmis-
sion.
INSTALLATION
(1) Install slave cylinder onto transmission.
(2) Install transmission assembly into the vehicle.
(3) Connect hydraulic line fto slave cylinder.
(4) Bleed the system.
FLYWHEEL
DIAGNOSIS AND TESTING
Common causes of flywheel problems:
• Incorrect bolt tightening
• Mounting the flywheel on a dirty crankshaft
flange
• Improper seating on the crankshaft flange shoul-
der
• Heat warpage
• Loose flywheel to crankshaft bolts
The flywheel should be replaced if warped or over-
heated. Do not machine the face of the flywheel
to correct a warped or overheated condition.
Clean the crankshaft flange and its mating surface
on the flywheel before assembling. dirt/grease in this
area could cause the flywheel to mis-align when
installing.
Use new bolts when mounting flywheel and secure
the bolts with Mopar Lock and Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over
tightening can distort the flywheel causing run out.
Fig. 9 TORQUE SEQUENCE
Fig. 10 Release Bearing/Hydraulic Slave Cylinder
1 - HYDRAULIC CLUTCH RELEASE
2 - BLEED SCREW
3 - TRANSMISSION
ZB
CLUTCH
6 - 9
CLUTCH DISC (Continued)
LINKAGE
DESCRIPTION
The hydraulic linkage consists of a clutch master
cylinder, reservoir, a clutch slave cylinder/release
bearing assembly and an interconnecting fluid line.
The clutch master cylinder push rod is connected
to the clutch pedal. The slave cylinder/release bear-
ing is mounted to the transmission front cover. The
clutch master cylinder is mounted on the driver side
of the dash panel adjacent to the brake master cylin-
der and booster assembly.
OPERATION
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. Depressing the clutch pedal develops
fluid pressure in the clutch master cylinder. This
pressure is transmitted to the slave cylinder through
a connecting line. In turn, the slave cylinder forces
the release bearing into the pressure plate dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc.
The slave cylinder/release bearing assembly has an
integral spring which preloads the release bearing
against the clutch diaphragm fingers to maintain
zero free-play.
MASTER CYLINDER
REMOVAL
(1) Remove master cylinder actuation rod to clutch
pedal clip.
(2) Remove anti-rotation pin from the toe box and
discard pin.
NOTE: Anti-rotation pin must not be reused.
(3) Disconnect clutch pedal position switch connector.
(4) Remove mounting screws on clutch fluid reser-
voir.
(5) Disconnect
hydraulic
line
quick
connector
located at clutch bell housing. Use special tool 6638
to separate quick connector.
CAUTION: Do not allow brake fluid to come in con-
tact with painted surfaces of the vehicle. Paint dam-
age may occur.
(6) Remove left inner fender for access to the mas-
ter cylinder.
(7) Twist clutch master cylinder a quarter turn
counterclockwise to remove from toe box.
(8) Remove assembly from vehicle.
INSTALLATION
(1) Twist clutch master cylinder a quarter turn
clockwise to install into toe box.
(2) Connect hydraulic line quick connector to
clutch bell housing.
(3) Install clutch fluid reservoir mounting screws.
(4) Install left inner fender.
(5) Connect clutch pedal position switch connector.
(6) Install new anti-rotation pin.
(7) Install master cylinder actuation rod to clutch
pedal clip.
(8) Bleed system.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The clutch pedal position switch is located on the
clutch master cylinder actuation rod (Fig. 11). The
switch is held in place by a plastic retaining clip. The
clutch master cylinder must be removed to replace
this switch.
OPERATION
The function of the clutch pedal position switch is
to prevent the engine starter from operating until the
clutch pedal is depressed. This switch will prevent
accidental engagement of starter while vehicle is in
gear.
Fig. 11 CLUTCH SWITCH LOCATION
1 - CLUTCH POSITION SWITCH CONNECTOR
2 - HYDRAULIC CLUTCH MASTER CYLINDER
3 - CLUTCH POSITION SWITCH
4 - CLUTCH ACTUATION ROD
6 - 10
CLUTCH
ZB
WARNING: UNDER NO CIRCUMSTANCES SHOULD
THE
CLUTCH
POSITION
SWITCH
BE
DISCON-
NECTED OR DISABLED.
There is no adjustment on the clutch position
switch. If the switch is not operating correctly, it
must be replaced as an assembly.
DIAGNOSIS AND TESTING
(1) Disconnect the connector on the clutch position
switch from the vehicle wiring harness.
(2) Place a ohmmeter across the terminals of the
switch connector. The switch should show no continu-
ity with the clutch pedal in the released (clutch
engaged) position.
(3) Slowly push the clutch pedal to the floor
(clutch disengaged). The ohmmeter should show con-
tinuity just before the pedal reaches the end of its
travel.
(4) If the clutch switch shows continuity with
clutch pedal up or no continuity with clutch pedal
down, the switch is defective. The switch has no ser-
viceable parts and should be replaced as an assem-
bly.
REMOVAL
(1) Disconnect the clutch pedal position switch
connector.
(2) Disconnect the clutch actuation rod from the
clutch pedal.
(3) Remove the clutch master cylinder from the toe
box.
(4) Remove the white clutch pedal position switch
retaining clip (Fig. 12).
(5) Push the switch up the rod slightly. Then pull
the bottom of the switch outward (Fig. 13).
Fig. 12 SWITCH RETAINER CLIP
1 - RETAINING CLIP
Fig. 13 SWITCH REMOVAL
1 - CLUTCH SWITCH
2 - CLUTCH ACTUATION ROD
3 - CLUTCH MASTER CYLINDER
ZB
CLUTCH
6 - 11
CLUTCH PEDAL POSITION SWITCH (Continued)
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