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Clutch Disc: Installation

  1. Inspect clutch release bearing and lever for excessive wear and replace as necessary.
  2. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed.
  3. Inspect the clutch disc for the side marked "FLYWHEEL SIDE".
  4. Apply a very light coating of grease to the splines in the clutch disc hub.
  5. Position the flywheel onto the engine crankshaft.
  6. Install the bolts to hold the flywheel to the crankshaft. Tighten the bolts to 95 N.m (70 ft. lbs.).
  7. Position the clutch disc to the flywheel.
  8. Install the clutch pressure plate to the flywheel. Finger tighten the pressure plate bolts.
  9. Use Clutch Alignment Tool 6724 to position the clutch disc to the center of the flywheel.
  10. Tighten the clutch pressure plate bolts in a crisscross pattern to 28 N.m (250 in. lbs.).
  11. Install transaxle into position. Be sure to carefully guide the input shaft splines through the clutch disc. It may be necessary to slightly rotate the transaxle or flywheel to allow the splines to engage.
  12. Install transaxle-to-engine mounting bolts and tighten to 108 N.m (80 ft. lbs.).
  13. Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount bracket. Install mount bolt and tighten to 108 N.m (70 ft. lbs.). (Figure).
  14. Remove screw jack.
  15. Install starter motor and tighten bolts to 54 N.m (40 ft. lbs.). Make sure to fasten ground cable to upper starter bolt as shown in. (Figure).
  16. Connect starter electrical harness and tighten positive cable nut to 10 N.m (90 in. lbs.).
  17. Install both front half shafts. (Refer to AXLE SHAFTS ).
  18. Fill transaxle with suitable amount of Mopar® ATF+4 (Automatic Transmission Fluid-Type 9602). Fill height is 3/16" (4.76 mm) below bottom of fill hole.
  19. Lower vehicle.
  20. Connect vehicle speed sensor connector. (Figure).
  21. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips. (Figure).
  22. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
  23. Connect back-up lamp switch connector.
  24. Connect ground strap to transaxle upper mount bracket.
  25. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery.
  26. Install the air cleaner/throttle body assembly as follows:
    1. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assembly.
    2. Install assembly into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 N.m (120 in. lbs.).
    3. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N.m (40 in. lbs.).
    4. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
    5. Connect proportional purge solenoid (PPS) and crankcase vent hose from throttle body.
  27. Connect the battery cables.
  28. Road test vehicle and inspect for leaks.
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