Dodge Ram Truck Models & Years Covered in the above Service Manuals:
2001 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.9 L 6 cyl. MPI Gasoline (5.9L), 5.2 L 8 cyl. MPI Gasoline (5.2L), 5.2 L 8 cyl. (CNG) (5.2L), 5.9 L 8 cyl. MPI Gasoline, 5.9 L 8 cyl. MPI Gasoline (Heavy Duty) (5.9L), 5.9 L 6 cyl. Turbo Diesel (5.9L), 8.0 L 10 cyl. MPI Gasoline (8.0L) Models.
2002 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.7L 6 cyl. MPI Gasoline 3.7 L, 4.7L 8 cyl. MPI Gasoline 4.7 L, 5.7L 8 cyl. SMPI Gasoline 5.7 L, 5.9L 6 cyl. Turbo Diesel 5.9 L
5.9L 6 cyl. Turbo Diesel High Output 5.9 L, 8.0L 10 cyl. MPI Gasoline 8.0 L, 5.9L 8 cyl. SMPI Gasoline Light Duty 5.9 L Models
2003 Dodge Ram 1500, 2500 & 3500 Service : 3.7L 6 cyl. MPI Gasoline, 4.7L 8 cyl. MPI Gasoline, 5.7L 8 cyl. SMPI Gasoline, 5.9L 6 cyl. Turbo Diesel, 5.9L 6 cyl. Turbo Diesel High Output, 8.0L 10 cyl. MPI Gasoline, 5.9L 8 cyl. SMPI Gasoline Light Duty Models.
For the complete clutch service procedures including picture illustrations see service manual links at the top of the page for exact year and model of your truck as clutch procedures differ for year and model dodge ram truck.
CLUTCH
CLUTCH DESCRIPTION
The clutch mechanism consists of a flywheel, a single, dry-type disc, and a diaphragm style clutch cover (Fig. 1). A hydraulic linkage is used to operate the clutch release bearing and fork. The flywheel is bolted to the rear flange of the crankshaft. The clutch pressure plate is bolted to the flywheel with the clutch disc located between these two components. The clutch system provides the mechanical, but still easily detachable, link between the engine and the transmission. The system is designed to ensure that the full torque output of the engine is transfered to the transmission while isolating the transmission from the engine firing pulses to minimize concerns such as gear rattle.
DIAGNOSIS AND TESTING
A road test and component inspection is recommended to determine a clutch problem. During a road test, drive the vehicle at normal speeds. Shift the transmission through all gear ranges and observe clutch action. If the clutch chatters, grabs, slips or does not release properly, remove and inspect the clutch components. If the problem is noise or hard shifting, further diagnosis may be needed as the transmission or another driveline component may be at fault.
SPECIFICATIONS - TORQUE SPECIFICATIONS Refer to service manual link at top of page.
CLUTCH DISC
REMOVAL
(1) Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. (2) Remove transmission and transfer case, if equipped. (3) If pressure plate will be reused, mark the position on flywheel with paint or scriber (Fig. 3). Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it.
Refer to service manual link at top of page for complete removal and installlation, it includes picture digrams and step-by step procedures.
INSTALLATION
(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.
(4) Install alignment tool in pilot bearing and position disc on the flywheel.
See Service Manual for Complete procedures
CLUTCH HOUSING
DIAGNOSIS AND TESTING
The clutch housing maintains alignment between the crankshaft and transmission input shaft. Misalignment can cause clutch noise, hard shifting, incomplete release and chatter. Also premature pilot bearing, cover release fingers and clutch disc wear. In severe cases, it can cause premature wear of the transmission input shaft and front bearing.
NOTE: Only the NV4500 clutch housing can be checked using the following bore and face runout procedures. The NV5600 clutch housing is a integral part of the transmission and can only be checked off the vehicle.
CLUTCH HOUSING BORE RUNOUT
CAUTION: On diesel engines if housing bore runout exceeds 0.015 inch, the clutch housing/transmission adapter plate must be replaced. On gas engines if housing bore runout exceeds 0.053 in. the clutch housing must be replaced.
NOTE: Offset dowels are available for gas engines to correct housing bore runout. They are not available for diesel engines.
(1) Remove the clutch housing.
(2) Remove the clutch cover and disc.
REMOVAL
(1) Remove transmission and transfer case (Fig. 15 - Service Manual at the top of the page contains all bolt locations, diagrams, illistrations & Step-by-step procedures).
(2) Remove the starter from the clutch housing.
(3) Remove clutch housing bolts and remove housing from the engine.
INSTALLATION
(1) Clean housing mounting surface of engine block with wax and grease remover.
(2) Verify that clutch housing alignment dowels are in good condition and properly seated.
(3) Transfer slave cylinder, release fork and boot, fork pivot stud and wire/hose brackets to new housing.
(4) Align and install clutch housing on transmission (Fig. 16). Tighten housing bolts closest to alignment dowels first and to the following torque values: See Manual for the complete procedures, illistrations and diagrams.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if equipped.
(2) Remove spring clip.
(3) Disconnect release bearing from release fork and remove bearing (Fig. 17).
INSTALLATION
(1) Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked.
(2) Inspect release lever and pivot stud. Be sure stud is secure and in good condition. Be sure fork is not distorted or worn. Replace fork spring clips if bent or damaged.
(3) Lubricate input shaft splines, bearing retainer slide surface, lever pivot ball stud, and release lever pivot surface with Mopart high temperature bearing grease.
Service Manual at the top of the page contains all bolt locations, diagrams, illistrations & Step-by-step procedures.
FLYWHEEL
when remounting a flywheel and secure the bolts with Mopar Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout.
DIAGNOSIS AND TESTING
Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are:
heat warpaimproper machining
incorrect bolt tightening
improper seating on crankshaft flange shoulder
foreign material on crankshaft flange
Flywheel machining is not recommended. The flywheelvclutch surface is machined to a unique contourvand machining will negate this feature.... See Service Manual
REMOVAL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 14
1 - FLYWHEEL
2 - PRESSURE PLATE FINGERS
3 - PIVOT POINT
4 - RELEASE BEARING PUSHED IN
5 - CLUTCH DISC ENGAGED
6 - CLUTCH DISC ENGAGED
7 - RELEASE BEARING
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
1 - INDICATOR PLUNGER
2 - DIAL INDICATOR
3 - CLUTCH HOUSING FACE
4 - INDICATOR MOUNTING STUD OR ROD
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N·m (200 IN. LBS.)
6 - SPRING CLIP
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
OPERATION
Leverage, clamping force and friction are what make the clutch work. The disc serves as the friction element and a diaphragm spring and pressure plate provide the clamping force. The clutch pedal, hydraulic linkage, release lever and bearing provide the leverage. The clutch master cylinder push rod is connected to the clutch pedal. When the clutch pedal is depressed, the slave cylinder is operated by the clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave cylinder mounted on the transmission housing. The release bearing is operated by a release fork pivoting on a ball stud mounted in the transmission housing. The release bearing then depresses the pressure plate spring fingers, releasing pressure on the clutch disc and allowing the engine crankshaft to spin independently of the transmission input shaft (Fig. 2).
