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Clutch Disc: Removal

  1. Raise hood.
  2. Disconnect and isolate both battery cables, remove battery hold down clamp and bolt, and remove battery.
  3. Remove air cleaner/throttle body assembly (Fig 1) as follows:
    Fig 1: Removing/Installing Air Cleaner Assembly
    G01032486Courtesy of DAIMLERCHRYSLER CORP.
    1. Disconnect proportional purge solenoid (PPS) and crankcase vent hose from throttle body.
    2. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
    3. Disconnect throttle body air duct at intake manifold.
    4. Remove mounting bolt and nut and partially remove air cleaner assembly. (Fig 1).
    5. Disconnect accelerator and speed control (if equipped) cables after the assembly is removed from position. Remove air cleaner assembly from vehicle.
  4. Remove battery tray from bracket.
  5. Disconnect ground cable at battery tray bracket.
  6. Disconnect back-up lamp switch connector.
  7. Using Tool 6638A, disconnect clutch hydraulic quick connect. (Fig 2 and Fig 3 ).
    Fig 2: Identifying Slave Cylinder & Hydraulic Supply Tube
    G01032487Courtesy of DAIMLERCHRYSLER CORP.
    Fig 3: Disconnecting/Reconnecting Hydraulic Circuit Using Tool 6638A
    G01032488Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove shift cable-to-bracket clips. (Fig 4).
    Fig 4: Disconnecting/Reconnecting Shift Cables At Transaxle
    G01032489Courtesy of DAIMLERCHRYSLER CORP.
  9. Disconnect shift selector and crossover cable from levers. (Fig 4). Remove cables and secure out of the way.
  10. Disconnect the vehicle speed sensor connector. (Fig 5).
    Fig 5: Disconnecting/Reconnecting Vehicle Speed Sensor Connector
    G01032490Courtesy of DAIMLERCHRYSLER CORP.
  11. Raise vehicle on hoist.
  12. Remove transaxle oil drain plug and drain oil into a suitable container.
  13. Remove both half shafts. (Refer to AXLE SHAFTS ).
  14. Remove starter motor. (Fig 6).
    Fig 6: Removing/Installing Starter Motor - Typical
    G01032491Courtesy of DAIMLERCHRYSLER CORP.
  15. Support engine at oil pan with screw jack and wood block.
  16. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house. (Fig 7).
    Fig 7: Removing/Installing Transaxle Upper Mount Thru-Bolt - Typical
    G01032492Courtesy of DAIMLERCHRYSLER CORP.
  17. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
  18. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts.
  19. Remove transaxle from vehicle.
  20. Remove bolts holding the clutch pressure plate to the flywheel.
  21. Remove the clutch pressure plate and disc from the flywheel.
  22. Remove the bolts holding the flywheel to the engine crankshaft.
  23. Remove the flywheel from the crankshaft.
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