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Disc Clutch: Installation

WARNING: This page is about a different car, the 2005 Dodge Pickup and 2005 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Check runout and free operation of new clutch disc.
  2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease.
  3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel.
    NOTE: Flywheel side is imprinted on the disc face.
  4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). See Fig 1.
    Fig 1: Clutch Disc And Pressure Plate
    GC0008254Courtesy of DAIMLERCHRYSLER CORP.
    1 - FLYWHEEL
    2 - PRESSURE PLATE AND DISC
    3 - ALIGNMENT TOOL
  5. Position pressure plate over disc (2) and onto the flywheel.
  6. Align and hold pressure plate in position and install bolts finger tight.
  7. Tighten bolts evenly and a few threads at a time in a diagonal pattern.
    CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover.
  8. Tighten pressure plate bolts to:
    • V6 & V8 Engines - 50 N.m (37 ft. lbs.)
    • V10 & Diesel Engines - 30 N.m (22.5 ft. lbs.)
  9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). See Fig 2.
    Fig 2: Lubrication Points
    GC0008255Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH HOUSING
    2 - FORK PIVOT BALL
    3 - RELEASE FORK
    4 - RELEASE BEARING BORE
    5 - LUBE POINTS
  10. Apply light coat of Mopar high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). See Fig 3.
    CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc.
    Fig 3: Input Shaft Lubrication Points
    GC0008256Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - BEARING RETAINER
    3 - SPLINE AND RELEASE BEARING SURFACE
  11. Wipe pilot bearing surface clean.
  12. Install release lever and bearing in clutch housing. Verify spring clip (2) that retain lever on pivot ball (4) and release bearing (3) clips (1) on lever (1) are installed properly. See Fig 4.
    NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission.
    Fig 4: Fork, Bearing And Spring Clips
    GC0008257Courtesy of DAIMLERCHRYSLER CORP.
  13. Install transmission and transfer case if equipped.
  14. Check fluid level in clutch master cylinder.
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