modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.

Models equipped with the 2.5L Turbo Diesel engine

utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it is highly
recommended that the clutch cover and disc be
replaced as a set.

Fig. 1 Modular Clutch Assembly—2.4L Gas Engines

1 - MODULAR CLUTCH ASSEMBLY

CLUTCH

6 - 1

Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines

1 - FLYWHEEL
2 - DISC
3 - PRESSURE PLATE

6 - 2

CLUTCH

CLUTCH (Continued)

RELEASE SYSTEM

All models utilize a hydraulic clutch release sys-

tem, conisting of a clutch master cylinder attached to
the clutch pedal (Fig. 3), and a slave cylinder fas-
tened to the transaxle which operates the clutch
release lever (Fig. 4). When the driver depresses the
clutch pedal, the master cylinder pushrod travels
through the cylinder bore, displacing fluid through
the master cylinder plumbing. This fluid displace-
ment forces the slave cylinder piston to travel, forc-
ing the clutch release bearing into the clutch
diaphragm spring via the release lever and leverage
(Fig. 5). This releases the clamping force on the
clutch disc, allowing the engine crankshaft to rotate
independently from the transaxle input shaft.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CLUTCH SYSTEM

Clutch problem diagnosis will generally require a

road test to determine the type of fault. Component
inspection will then determine the problem after road
testing.

Drive the vehicle at normal speeds during road

test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect

the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.

Fig. 3 Clutch Master Cylinder - Typical

1 - CLUTCH PEDAL
2 - BUSHING
3 - GROMMET
4 - MASTER CYLINDER
5 - STOP

Fig. 4 Slave Cylinder Removal/Installation

1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB

Fig. 5 Release Bearing and Lever

1 - RELEASE LEVER
2 - RELEASE BEARING

CLUTCH

6 - 3

CLUTCH (Continued)

SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER

CONDITION

POSSIBLE CAUSES

CORRECTION

CLUTCH DISC FACING
COVERED WITH OIL OR
GREASE

Oil leak at engine rear main or
transaxle input shaft seal.

Correct leak and replace modular clutch
assembly (2.4L Gas) or clutch cover and disc
(2.5L TD).

Too much grease applied to splines
of disc and input shaft.

Apply lighter coating of grease to splines.

NO FAULT FOUND WITH
CLUTCH
COMPONENTS

Problem actually related to
suspension or driveline component.

Further diagnosis required. Check engine/
transmission mounts, suspension attaching
parts and other driveline components as
needed.

Engine related problems.

Check EFI and ignition systems.

PARTIAL ENGAGEMENT
OF CLUTCH DISC

Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Clutch disc damaged or distorted.

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Clutch misalignment.

Verify modular clutch pilot plate alignment to
crankshaft. Replace the modular clutch
assembly (2.4L Gas) or clutch cover and disc
(2.5L TD) if the pilot plate is loose or bent.

Improper transaxle-to-engine
installation.

Verify transaxle is properly installed to
engine.

SERVICE DIAGNOSIS - CLUTCH SLIPS

CONDITION

POSSIBLE CAUSES

CORRECTION

DISC FACING WORN
OUT

Normal wear.

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Driver frequently rides (slips) clutch,
results in rapid wear, overheating.

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

Insufficient clutch cover diaphragm
spring tension

Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).

CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE

Leak at rear main oil seal or
transaxle input shaft seal

Replace leaking seals. Replace modular
clutch assembly (2.4L Gas) or clutch cover
and disc (2.5L TD).

Excessive amount of grease applied
to input shaft splines

Apply less grease to input shaft. Replace
modular clutch assembly (2.4L Gas) or clutch
cover and disc (2.5L TD).

Road splash, water entering housing

Seal housing. Inspect clutch assembly.

CLUTCH IS RUNNING
PARTIALLY
DISENGAGED

Release bearing sticking or binding,
does not return to normal running
position.

Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.

Clutch pedal not returning to static
position.

Inspect pedal assembly for damage and/or
obstructions. Replace componnents as
necessary.

Clutch master cylinder or pushrod
damaged causing high preload.

Replace clutch master cylinder assembly.

Slave cylinder binding or stuck.

Replace slave cylinder.

6 - 4

CLUTCH

CLUTCH (Continued)

Content .. 674 675 676 677 ..