clutch assembly (Fig. 1). The clutch is located
between the engine and manual transaxle in the
transaxle bellhousing. The 2.0/2.4L clutch system
consists of the following components:

• Flywheel

• Clutch Disc

• Pressure Plate

• Diaphragm Spring

• Cover

HYDRAULIC

The clutch hydraulic system is a self-contained sys-

tem that consists of a clutch master/slave cylinder
assembly and a fluid reservoir (Fig. 2).

FLUID

CAUTION: Never use any type of petroleum-based
fluid (engine oil, transmission oil, power steering
fluid, etc.) in the clutch hydraulic system. Use of
such fluids will result in master/slave cylinder seal
damage, and cause a failure of the hydraulic clutch
release system.

NOTE: The clutch hydraulic system and replace-
ment components are pre-filled, and under normal
operating conditions, additional fluid is not required
for the life of the vehicle.

PL/SRT-4

CLUTCH

6 - 1

The fluid required for use in the clutch hydraulic

system is brake fluid conforming to DOT 3 specifica-
tions and J1703 standards. No other type of fluid is
recommended or approved for use in the clutch
hydraulic system. use only Mopar

t brake fluid or

equivalent from a tightly sealed container.

OPERATION

MECHANICAL

The clutch assembly is designed to transmit power

from the engine to the manual transaxle. This is
accomplished by the friction and clamping force gen-
erated when the spring loaded pressure plate locks
the clutch disc to the flywheel (Fig. 3). The clutch
disc, which is splined to the transaxle input shaft,
transmits power until the center of the diaphragm
spring is depressed, and the clamp force is removed
from the disc.

HYDRAULIC

The clutch hydraulic system is responsible for

engaging and disengaging the clutch. Depressing the
clutch pedal develops fluid pressure in the clutch
master cylinder. This pressure is transmitted to the
slave cylinder through a connecting line. In turn, the
slave cylinder operates the clutch release lever (Fig.
2).

Fig. 1 Modular Clutch Assembly

1 - MODULAR CLUTCH ASSEMBLY

Fig. 2 Clutch Hydraulic System—Typical

1 - RESERVOIR
2 - MASTER CYLINDER
3 - PEDAL ASSEMBLY
4 - SLAVE CYLINDER

Fig. 3 Clutch Coupling Powerflow - Typical

6 - 2

CLUTCH

PL/SRT-4

CLUTCH (Continued)

The slave cylinder spring causes the release lever

to hold the release bearing in constant contact with
the diaphragm spring (release bearing preload). Dur-
ing a clutch pedal actuation, the hydraulic fluid pres-
sure applies additional force to the release lever. As
additional force is applied, the bearing presses the
diaphragm spring fingers inward on the fulcrums.
This action moves the pressure plate rearward,
relieving clamp force on the disc.

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.

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 clutch assembly.

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 clutch assembly.

Clutch disc damaged or distorted.

Replace clutch assembly.

Clutch misalignment.

Verify modular clutch pilot plate alignment
to crankshaft. Replace the clutch assembly
if the pilot plate is loose or bent.

SERVICE DIAGNOSIS - CLUTCH SLIPS

CONDITION

POSSIBLE CAUSES

CORRECTION

DISC FACING WORN OUT

Normal wear.

Replace clutch assembly.

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

Replace clutch assembly.

Insufficient clutch cover diaphragm
spring tension

Replace clutch assembly.

CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE

Leak at rear main oil seal or
transaxle input shaft seal

Replace leaking seals. Replace clutch
assembly.

Excessive amount of grease applied
to input shaft splines

Apply less grease to input shaft. Replace
clutch assembly

PL/SRT-4

CLUTCH

6 - 3

CLUTCH (Continued)

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