Clutch Disc And Pressure Plate: Installation: 1.6L

Fig 1: Release Bearing And Lever

Courtesy of DAIMLERCHRYSLER CORP.

1 - RELEASE BEARING

2 - LEVER

1. Inspect clutch release bearing (1) and lever (2) for excessive wear and replace as necessary. See Fig 1.
   Fig 2: Identifying Flywheel And Crankshaft Flange

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - FLYWHEEL

   2 - BOLT (8)

   3 - CRANKSHAFT FLANGE

2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and rust have been removed. See Fig 2.
3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel (1) onto the engine crankshaft.
4. Install and torque the flywheel-to-crankshaft bolts (2) to 95 N.m (70 ft.lbs.).
   Fig 3: Clutch Disc and Pressure Plate

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - FLYWHEEL

   2 - CLUTCH DISC

   3 - PRESSURE PLATE

   4 - BOLT (6)

5. Apply a very light coating of grease to the splines in the clutch disc hub.
6. Position the clutch disc (2) to the flywheel. Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1). See Fig 3.
7. Install the clutch pressure plate (3) to the flywheel (1) and clutch disc (2). Finger tighten the six pressure plate-to-flywheel bolts (4).
   Fig 4: Aligning Clutch Disc-Typical

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - FLYWHEEL

   2 - PRESSURE PLATE

   3 - CLUTCH DISC ALIGNMENT TOOL

8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc to the center of the flywheel (1). See Fig 4.
   Fig 5: Clutch Disc and Pressure Plate

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - FLYWHEEL

   2 - CLUTCH DISC

   3 - PRESSURE PLATE

   4 - BOLT (6)

9. Tighten pressure plate bolts (4) evenly and in rotation a few threads at a time. See Fig 5.The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate.  .
10. Using a "criss-cross" pattern, torque the pressure plate-to-flywheel bolts to 28 N.m (250 in.lbs.). Remove the clutch disc alignment tool.
11. Apply light coat of Mopar® High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft.
    CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc.
12. Install transaxle,
    • For G288 M/T, (Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) .
    • For T350 M/T, (Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) .