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Rear Clutch: Assembly

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Soak clutch discs in transmission fluid while assembling other clutch parts.
  2. Install new seal rings on clutch retainer hub and input shaft, if necessary, (Fig 1) and (Fig 2).
    1. Be sure clutch hub seal ring is fully seated in groove and is not twisted.
    Fig 1: Installing Rear Clutch Retainer And Input Shaft Seal Ring
    G02657767Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: Identifying Input Shaft Seal Ring
    G02657768Courtesy of DAIMLERCHRYSLER CORP.
  3. Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then press input shaft into retainer (Fig 3). Use a suitably sized press tool to support retainer as close to input shaft as possible.
    4. Fig 3: Pressing Input Shaft Into Rear Clutch Retainer
    G02657769Courtesy of DAIMLERCHRYSLER CORP.
  4. Install input shaft snap-ring (Figure).
  5. Invert retainer and press input shaft in opposite direction until snap-ring is seated.
  6. Install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer.
  7. Lubricate lip of piston seals with generous quantity of Mopar® Door Ease. Then lubricate retainer hub and bore with light coat of transmission fluid.
  8. Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary.
    CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
  9. Install piston spring in retainer and on top of piston (Fig 4). Concave side of spring faces downward (toward piston).
    10. Fig 4: Identifying Piston Spring/Wave Spring
    G02657770Courtesy of DAIMLERCHRYSLER CORP.
  10. Install wave spring in retainer (Fig 4). Be sure spring is completely seated in retainer groove.
  11. Install bottom pressure plate (Figure). Ridged side of plate faces downward (toward piston) and flat side toward clutch pack.
  12. Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required) (Figure).
  13. Install top pressure plate.
  14. Install selective snap-ring. Be sure snap-ring is fully seated in retainer groove.
  15. Using a suitable gauge bar and dial indicator, measure clutch pack clearance (Fig 5).
    Fig 5: Checking Rear Clutch Pack Clearance
    G02657771Courtesy of DAIMLERCHRYSLER CORP.
    1. Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate (Fig 5).
    2. Using two small screw drivers, lift the pressure plate and release it.
    3. Zero the dial indicator.
    4. Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading.

    Clearance should be 0.559-0.914 mm (0.022-0.036 in.). If clearance is incorrect, steel plates, discs, selective snap ring and pressure plates may have to be changed.

    The selective snap-ring thicknesses are:

    • 0.107-0.109 in.
    • 0.098-0.100 in.
    • 0.095-0.097 in.
    • 0.083-0.085 in.
    • 0.076-0.078 in.
    • 0.071-0.073 in.
    • 0.060-0.062 in.
  16. Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer (Fig 6). Use enough petroleum jelly to hold washer in place.
    Fig 6: Installing Rear Clutch Thrust Washer
    G02657772Courtesy of DAIMLERCHRYSLER CORP.
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