Dodge Nitro. Manual - part 500

 

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Dodge Nitro. Manual - part 500

 

 

Fig. 9: Dual Mass Flywheel 
Courtesy of CHRYSLER LLC 

The Dual Mass Flywheel is used on all engines. The flywheel incorporates the ring gear (5) around the outer 
circumference to mesh with the starter to permit engine cranking. The primary flywheel (6) side is bolted to the 
crankshaft. The secondary flywheel (3) side serves as the driving member to the clutch disc. Internal springs (4) 
between the flywheels are use to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and 
should never be taken apart. 

DIAGNOSIS AND TESTING 

FLYWHEEL 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

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  

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. 

REMOVAL 

REMOVAL 

1. Remove transmission.  

2. Remove clutch pressure plate and disc.  

3. Remove flywheel-to-crankshaft bolts and remove flywheel assembly.  

INSTALLATION 

INSTALLATION 

1. Clean the surfaces of the flywheel and pressure plate.  

2. Install flywheel with new bolts and tighten in a criss-cross pattern. Tighten bolts to 95 N.m (70 ft. lbs.). 

On 2.8L diesel engine tighten bolts to 25 N.m (180 ft. lbs.) then rotate wrench 60°.  

3. Install clutch disc and pressure plate.  

4. Install transmission.  

BEARING-PILOT 

REMOVAL 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

BEARING-PILOT 

1. Remove transmission.  

2. Remove pressure plate and clutch disc.  

3. Remove pilot bearing with an internal (blind hole) puller.  

INSTALLATION 

BEARING-PILOT 

Fig. 10: Identifying New Pilot Bearing & Clutch Alignment Tool 
Courtesy of CHRYSLER LLC 

1. Lubricate new bearing with Mopar® high temperature bearing grease or equivalent.  

2. Start new pilot bearing (1) into crankshaft by hand. Then seat bearing with clutch alignment tool (2).  

3. Install clutch disc and pressure plate.  

4. Install transmission.  

CYLINDER-MASTER 

REMOVAL 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

REMOVAL 

Fig. 11: Identifying Actuator Rod & Clutch Pedal Pin 
Courtesy of CHRYSLER LLC 

1. Pry actuator rod (1) off clutch pedal pin (2). 

Fig. 12: Identifying Hose, Wiring Harness & Hydraulic Line 
Courtesy of CHRYSLER LLC 

2. Remove hose (1) from clutch master cylinder and plug hose to prevent fluid loss.  

3. Disconnect wiring harness (3) from pedal position switch.  

4. Pull the hydraulic line (2) clip and remove line from bottom of clutch master cylinder. 

 

2007 Dodge Nitro R/T 

2007 CLUTCH Clutch - Nitro

  

 

 

 

 

 

 

 

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