Dodge Nitro. Manual - part 496

Fig. 754: Body In White Complete (3 Of 4) 
Courtesy of CHRYSLER LLC 

Fig. 755: Body In White Complete (4 Of 4) 
Courtesy of CHRYSLER LLC 

 

2007 Dodge Nitro R/T 

2007 ACCESSORIES AND EQUIPMENT Body - Nitro

  

2007 CLUTCH

Clutch - Nitro 

WARNING 

CLUTCH 

DIAGNOSIS AND TESTING 

CLUTCH 

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. 

CLUTCH CONTAMINATION 

Fluid contamination is a frequent cause of clutch malfunctions. Oil, water or clutch fluid on the clutch disc and 
pressure plate surfaces will cause chatter, slip and grab. Inspect components for oil, hydraulic fluid or 
water/road splash contamination. 

Oil contamination indicates a leak at either the rear main seal or transmission input shaft. Clutch fluid leaks are 
usually from damaged slave cylinder push rod seals. Heat buildup caused by slippage between the pressure 
plate, disc and flywheel can bake the oil residue onto the components. The glaze-like residue ranges in color 
from amber to black. 

Road splash contamination is dirt/water entering the clutch housing due to loose bolts, housing cracks. Driving 
through deep water puddles can force water/road splash into the housing through such openings. 

IMPROPER RELEASE OR CLUTCH ENGAGEMENT 

WARNING:

DaimlerChrysler does not manufacture any vehicles that utilize asbestos 
containing products. Manual clutches on older model vehicles and 
aftermarket manual clutch facings may contain asbestos. Refer to 
aftermarket product packaging for product information. Regardless if the 
product contains asbestos or not, dust and dirt can accumulate on 
manual clutch parts during normal use. Follow all recommended safety 
practices prescribed by the occupational safety and health administration 
(OSHA) and the environmental safety agency (EPA), for the handling and 
disposal of products containing asbestos. Failure to follow these 
instructions may result in personal injury

NOTE:

Vehicles equipped with a Dual Mass Flywheel may produce a rattle when the 
engine is shut off. This noise is considered normal.

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

Clutch release or engagement problems are caused by wear or damage clutch components. A visual inspection 
of the release components will usually reveal the problem part. 

Release problems can result in hard shifting and noise. Look for leaks at the clutch cylinders and 
interconnecting line and loose slave cylinder bolts. Also worn/loose release fork, pivot stud, clutch disc, 
pressure plate or release bearing. 

Engagement problems can result in slip, chatter/shudder and noisy operation. The causes may be clutch disc 
contamination, wear, distortion or flywheel damage. Visually inspect to determine the actual cause of the 
problem. 

CLUTCH MISALIGNMENT 

Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment 
caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch 
release. 

PRESSURE PLATE AND DISC RUNOUT 

Check the clutch disc before installation. Axial (face) runout of a new disc should not exceed 0.50 mm (0.020 
in.). Measure runout about 6 mm (1/4 in.) from the outer edge of the disc facing. Obtain another disc if runout is 
excessive. 

Check condition of the clutch before installation. A warped cover or diaphragm spring will cause grab and 
incomplete release or engagement. Be careful when handling the cover and disc. Impact can distort the cover, 
diaphragm spring, release fingers and the hub of the clutch disc. 

Use an alignment tool when positioning the disc on the flywheel. The tool prevents accidental misalignment 
which could result in cover distortion and disc damage. 

A frequent cause of clutch cover distortion (and consequent misalignment) is improper bolt tightening. 

FLYWHEEL RUNOUT 

Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm 
(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 warpage  

Improper machining  

Incorrect bolt tightening  

Improper seating on crankshaft flange shoulder  

Foreign material on crankshaft flange 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and 
machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or 
with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 
in.). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 
0.076 mm (0.003 in.). Excessive stock removal can result in flywheel cracking or warpage after installation; it 
can also weaken the flywheel and interfere with proper clutch release. 

Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the 
flywheel causing excessive runout. Use new bolts 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 CHART 

The Diagnosis Chart describes common clutch problems, causes and correction. Conditions, causes and 
corrective action are outlined in the indicated columns. 

DIAGNOSIS CHART 

CONDITION

POSSIBLE CAUSES

CORRECTION

Disc facing worn out

1. Normal wear.

1. Replace cover and disc.

2. Driver frequently rides (slips) 
the clutch. Results in rapid 
overheating and wear.

2. Replace cover and disc.

3. Insufficient clutch cover 
diaphragm spring tension.

3. Replace cover and disc.

Clutch disc facing contaminated 
with oil, grease, or clutch fluid.

1. Leak at rear main engine seal or 
transmission input shaft seal.

1. Replace appropriate seal.

2. Excessive amount of grease 
applied to the input shaft splines.

2. Remove grease and apply the 
correct amount of grease.

3. Road splash, water entering 
housing.

3. Replace clutch disc. Clean 
clutch cover and reuse if in good 
condition.

4. Slave cylinder leaking.

4. Replace hydraulic clutch 
linkage.

Clutch is running partially 
disengaged.

1. Release bearing sticking or 
binding and does not return to the 
normal running position.

1. Verify failure. Replace the 
release bearing and transmission 
front bearing retainer as necessary.

Flywheel below minimum 
thickness specification.

1. Improper flywheel machining. 
Flywheel has excessive taper or 
excessive material removal.

1. Replace flywheel.

Clutch disc, cover and/or 
diaphragm spring warped or 
distorted.

1. Rough handling. Impact bent 
cover, spring, or disc.

1. Replace disc or cover as 
necessary.

2. Improper bolt tightening 
procedure.

2. Tighten clutch cover using 
proper procedure.

Facing on flywheel side of disc 
torn, gouged, or worn.

1. Flywheel surface scored or 
nicked.

1. Correct surface condition if 
possible. Replace flywheel and 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro