2012 CLUTCH

Clutch System - Ram Pickup

WARNING
WARNING

WARNING: Chrysler does not manufacture any vehicles or replacement parts that
contain asbestos. Aftermarket products may or may not contain asbestos.
Refer to aftermarket product packaging for product information. Whether
the product contains asbestos or not, dust and dirt can accumulate on
manual clutch parts during normal use. Follow practices prescribed by
appropriate regulations for the handling, processing and disposing of
dust and debris.

DIAGNOSIS AND TESTING

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DIAGNOSIS AND TESTING - CLUTCH

Road test and inspect components to determine a clutch problem. Road test the vehicle at normal speeds. Shift
the transmission through all gear ranges and observe clutch action. If clutch chatters, grabs, slips or does not
release properly, remove and inspect clutch components. If problem is noise or hard shifting, further diagnosis
may be needed to the transmission and driveline component.

CLUTCH CONTAMINATION

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. 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

Clutch release or engagement problems can be caused by worn or damaged clutch components.

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

Engagement problems can cause slip, chatter/shudder and noisy operation. The causes may be clutch disc
contamination, wear, distortion or flywheel damage.
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.

CLUTCH COVER 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

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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.

Common causes of runout are:

 heat warpage
 improper machining
 incorrect bolt tightening
 improper seating on crankshaft flange shoulder
 foreign material on crankshaft flange

Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with turning 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.).

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. Overtightening can distort the flywheel hub causing runout.

DIAGNOSIS CHART

The diagnosis charts describe common clutch problems, causes and correction. Refer to DIAGNOSIS
CHART.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) 2. Replace cover and disc.
the clutch. Results in rapid
overheating and wear.
3. Insufficient clutch cover 3. Replace cover and disc.
diaphragm spring tension.
Clutch disc facing contaminated 1. Leak at rear main engine seal or 1. Replace appropriate seal.
with oil, grease, or clutch fluid. transmission input shaft seal.
2. Excessive amount of grease 2. Remove grease and apply the
applied to the input shaft splines.
correct amount of grease.
3. Road splash, water entering 3. Replace clutch disc. Clean
housing. clutch cover and reuse if in good
condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch

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linkage.
Clutch is running partially 1. Release bearing sticking or 1. Verify failure. Replace the
disengaged. binding and does not return to the release bearing and transmission
normal running position. front bearing retainer as necessary.
2. Release lever installed
incorrectly.
3. Automatic wear adjustment
incorrect.
Flywheel below minimum 1. Improper flywheel machining. 1. Replace flywheel.
thickness specification. Flywheel has excessive taper or
excessive material removal.
Clutch disc, cover or diaphragm 1. Rough handling. Impact bent 1. Replace disc or cover as
spring warped or distorted. cover, spring, or disc. necessary.
2. Improper bolt tightening 2. Tighten clutch cover using
procedure. proper procedure.
Facing on flywheel side of disc 1. Flywheel surface scored or 1. Correct surface condition if
torn, gouged or worn. nicked. possible. Replace flywheel and
disc as necessary.
2. Clutch disc sticking or binding 2. Inspect components and
on transmission input shaft. correct/replace as necessary.
Clutch disc facing burnt. Flywheel 1. Frequent operation under high 1. Correct condition of flywheel
and cover pressure plate surfaces loads or hard acceleration and pressure plate surface.
heavily glazed. conditions. Replace clutch cover and disc.
Alert driver to problem cause.
2. Driver frequently rides (slips) 2. Correct condition of flywheel
clutch. Results in rapid wear and and pressure plate surface.
overheating of disc and cover. Replace clutch cover and disc.
Alert driver to problem cause.
Clutch disc binds on input shaft 1. Clutch disc hub splines 1. Clean, smooth and lubricate hub
splines. damaged during installation. splines if possible. Replace disc if
necessary.
2. Input shaft splines rough, 2. Clean, smooth, and lubricate
damaged, or corroded. shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel or 1. Clutch not used for an extended 1. Sand rusted surfaces with 180
pressure plate. period of time (e.g. long term grit sanding paper. Replace clutch
vehicle storage). cover and flywheel if necessary.
Pilot bearing seized, loose or 1. Bearing cocked during 1. Install a new bearing.
rollers are worn. installation.
2. Bearing defective. 2. Install a new bearing.
3. Bearing not lubricated. 3. Install a new bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage 1. Low hydraulic linkage fluid 1. Add hydraulic linkage fluid.

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properly. level.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring 4. Replace clutch cover.
bent or warped.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot 6. Replace fork or pivot as
loose or damaged. necessary.
7. Clutch master or slave cylinder 7. Replace hydraulic linkage
failure. assembly.
8. Incorrect slave cylinder
installed.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not 2. Lubricate master cylinder
lubricated. bushing.
3. Pedal bushings worn out or 3. Replace and lubricate bushings.
cracked.
4. Rough surface on front bearing 4. Replace front bearing retainer.
retainer.
Clutch master or slave cylinder 1. Master or slave cylinder 1. Replace clutch hydraulic
plunger dragging or binding components worn or corroded. linkage assembly.
Release bearing is noisy. 1. Release bearing defective or 1. Replace release bearing.
damaged.
Contact surface of release bearing 1. Clutch cover incorrect or 1. Replace clutch cover and
damaged. release fingers bent or distorted. release bearing.
 2. Release bearing defective or 2. Replace the release bearing.
damaged.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for
damage/alignment. Repair as
necessary.
Partial engagement of clutch disc. 1. Clutch pressure plate position 1. Replace clutch disc and cover.
One side of disc is worn and the incorrect.
other side is glazed and lightly 2. Clutch cover, spring, or release 2. Replace clutch disc and cover.
worn. fingers bent or distorted.
3. Clutch disc damaged or 2. Replace clutch disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate and
clutch housing. Correct as

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necessary.

SPECIFICATIONS
SPECIFICATIONS

TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Slave Cylinder Nuts 23 17 -
Clutch Master Cylinder
28 21 -
Nuts
Pressure Plate Bolts -
30 22 -
Diesel
Release Bearing Pivot 23 17 -
Dual Mass Flywheel To
55 40 -
Adapter Bolts
Dual Mass Flywheel
Adapter To Crankshaft 137 100 -
Bolts

SPECIAL TOOLS
SPECIAL TOOLS

7471B - Barring Tool

(Originally Shipped In Kit Number(s) 6860.)

BEARING, CLUTCH RELEASE

REMOVAL

REMOVAL

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Fig. 1: Clutch Release Components
Courtesy of CHRYSLER GROUP, LLC

1. Remove transmission and transfer case, if equipped.

2. Remove spring clip (6).
3. Disconnect release bearing (4) from release lever (3) and remove bearing.

INSTALLATION

INSTALLATION

Fig. 2: Release Lever & Pivot Stud

Courtesy of CHRYSLER GROUP, LLC

1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is
 scored, worn, or cracked.
2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not
distorted or worn. Replace fork spring clips if bent or damaged.
3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface
with Mopar™ high temperature bearing grease.

CAUTION: The release fork is not symmetrical and must be installed with the
slots and part number stamping toward the ball stud side. Part
number stamping will be right side up when installed correctly.
Failure to install the release fork correctly will result in clutch
slippage and damage.

4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and
release lever is installed properly. Rear side of release lever has one end with a raised area, which goes
toward the slave cylinder side of the transmission.
5. Install transmission and transfer case.

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DISC, CLUTCH
ADJUSTMENTS

ADJUSTMENTS

Fig. 3: Compressing Diaphragm Until Tension Is Released

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Improper adjustment will shorten clutch disc life.

NOTE: Perform the following procedure, when replacing only the clutch disc on Diesel
vehicles with Dual Mass Flywheel and the original self-adjusting pressure plate.
The pressure plate must be reset before installing a new disc.

NOTE: It is recommended that the cover and disc be replaced as a unit. New units sold
are pre-adjusted.

1. Support pressure plate flange with press blocks (3) on a press.

2. Center press ram (2) on the pressure plate diaphragm spring fingers (1).
3. Compress the diaphragm spring fingers (1), until tension is released from the stepped adjusting ring.

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Fig. 4: Stepped Adjusting Rings & Pressure Plate
Courtesy of CHRYSLER GROUP, LLC

4. Place two screwdrivers against two of the three stepped adjusting rings (1) tension spring stops, just
ahead of the adjusting ring tension springs on the pressure plate (2).
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Fig. 5: Stepped Adjust Ring & Pressure Plate
Courtesy of CHRYSLER GROUP, LLC

5. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until the coil springs are fully
compressed. Then hold adjusting ring while releasing the press pressure.
6. Remove the screwdrivers. The pressure plate is know adjusted for a new clutch disc.

REMOVAL

REMOVAL
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Fig. 6: Marks On Pressure Plate & Flywheel
Courtesy of CHRYSLER GROUP, LLC

1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts.
2. Remove transmission and transfer case, if equipped.

Fig. 7: Alignment Tool & Pressure Plate

Courtesy of CHRYSLER GROUP, LLC

3. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place
while removing bolts.
4. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping
the plate.
5. Remove bolts completely and remove pressure plate, disc and alignment tool.
INSTALLATION

INSTALLATION

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Fig. 8: Alignment Tool & Pressure Plate
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Before installing a new clutch disc on the Diesel engine with Dual Mass
Flywheel and the original self-adjusting pressure plate, the pressure plate
must be reset. Refer to ADJUSTMENTS. Failure to reset the pressure will
result in damage to the clutch disc and loss of function.

NOTE: It is recommended that the cover and disc be replaced as a unit. New units sold
are pre-adjusted.

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.

NOTE: Flywheel side is imprinted on the disc face.

4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1).
5. Position pressure plate over disc (2) and onto the flywheel.

NOTE: Over the wear life of a clutch disc the pressure plate will lose some of it's
clamp load. It is recommended when replacing a worn clutch, the pressure
plate is replaced at the same time.

6. Align and hold pressure plate in position and install bolts finger tight.
7. Tighten bolts evenly and a few threads at a time in a diagonal pattern.
 CAUTION: Bolts must be tightened evenly in a star pattern and to specified
torque to avoid warping pressure plate cover.

8. Tighten pressure plate bolts to 30 N.m (22 ft. lbs.).

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Fig. 9: Identifying Lubrication Points
Courtesy of CHRYSLER GROUP, LLC

9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar™ high temperature
bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud
(2).
 Fig. 10: Input Shaft Lubrication Points
Courtesy of CHRYSLER GROUP, LLC

10. Apply light coat of Mopar™ high temperature bearing grease to splines (3) of transmission input shaft (1)

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and to release bearing slide surface of the transmission front bearing retainer (2).

CAUTION: Do not over lubricate shaft splines. This can result in grease
contamination of the disc.

11. Wipe pilot bearing surface clean.

Fig. 11: Pivot Ball, Release Bearing & Spring Clips

Courtesy of CHRYSLER GROUP, LLC

12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4)
and release bearing (3) are installed properly.

NOTE: If release lever is installed correctly, the lever part number will be toward
the bottom of the transmission and right side up. There is also a stamped
 "I" in the lever which goes to the pivot ball side of the transmission.

13. Install transmission and transfer case if equipped.

14. Check fluid level in clutch master cylinder and depress clutch pedal several time.

FLYWHEEL
DESCRIPTION

DESCRIPTION

DUAL MASS FLYWHEEL

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Fig. 12: Dual Mass Flywheel
Courtesy of CHRYSLER GROUP, LLC

The Dual Mass Flywheel (1) is used on the Diesel engine with G56 transmission. The flywheel incorporates the
ring gear around the outer circumference to mesh with the starter to permit engine cranking. The primary
flywheel side is bolted to an adapter plate which is bolted to the crankshaft. The secondary flywheel side (2)
serves as the driving member to the clutch disc. Internal springs (3) are used to dampen energy. The Dual Mass
Flywheel is serviced as an assembly only and should never be taken apart.
Fig. 13: Internal Springs & Retainer
Courtesy of CHRYSLER GROUP, LLC

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The internal springs (2) and retainer (3) will be visible through the sight window (1). A visible retainer is not an
indication of a broken spring. It is also normal to have play up to 30 mm (1.18 inches).

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - FLYWHEEL

Fig. 14: Flywheel

Courtesy of CHRYSLER GROUP, LLC

Check flywheel (3) 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

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distort the flywheel hub causing runout.

Fig. 15: Dual Mass Flywheel & Springs

Courtesy of CHRYSLER GROUP, LLC

On a Dual Mass Flywheel (1) inspect all springs (2) for damage.

REMOVAL

REMOVAL
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Fig. 16: Pressure Plate Bolts Loosening Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Remove the transmission. Refer to REMOVAL .

NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the
flywheel and crank. This plate does not need to be removed.

2. Loosen pressure plate bolts (1-8) evenly, a few threads at a time and in a diagonal pattern to prevent
warping the plate.
3. Remove the eight pressure plate bolts (1-8) completely and remove pressure plate and disc.
 Fig. 17: Dust Cover & Bolts
Courtesy of CHRYSLER GROUP, LLC

4. Remove the dust cover bolts (1) and the dust cover (2).

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Fig. 18: Identifying Flexplate-To-Flywheel Bolt
Courtesy of CHRYSLER GROUP, LLC

5. Using the access hole, remove each flexplate-to-flywheel bolt (1). Use Barring Tool (special tool #7471B,
Barring Tool) to rotate the engine and flywheel.
6. Remove the flywheel.

INSTALLATION

INSTALLATION
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Fig. 19: Pressure Plate Bolts Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Install adapter plate.

2. Install adapter plate bolts and tighten evenly in sequence to 55 N•m (40 ft. lbs.).
3. Install clutch.
4. Install transmission.

LINKAGE
REMOVAL

REMOVAL
Fig. 20: Slave Cylinder & Nuts
Courtesy of CHRYSLER GROUP, LLC

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CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This
fitting should never be disconnected or tampered with. Once the hydraulic
line is connected to the slave cylinder, it should never be disconnected.

1. Raise and support vehicle.

2. Remove heat shield over hydraulic line.
3. Remove slave cylinder (2) nuts (1) on clutch housing.
4. Remove slave cylinder from clutch housing.

CAUTION: Do not allow release lever plunger to pivot more than 2° in either
direction in the slave cylinder bore. Allowing the plunger to pivot
more than 2° in the bore will cause fluid to bypass the seal and result
in fluid leakage.

5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange.
6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud.
7. Lower vehicle.
 Fig. 21: Clutch Master Cylinder, Rod Pin & Pedal Interlock Switch Connector
Courtesy of CHRYSLER GROUP, LLC

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8. Disconnect clutch pedal interlock switch connector (2).
9. Remove clutch master cylinder (1) rod pin (3).
10. Ensure cap on clutch cylinder reservoir is tight.
11. Remove clutch master cylinder nuts holding cylinder to the dash panel.
12. Remove clutch cylinders, reservoir and connecting lines from vehicle.

INSTALLATION

INSTALLATION

Fig. 22: Clutch Master Cylinder, Rod Pin & Pedal Interlock Switch Connector
Courtesy of CHRYSLER GROUP, LLC

1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line
against the dash panel and behind all engine hoses and wiring.
 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye.
3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 N.m (21 ft.
lbs.).
4. Install clutch master cylinder push rod pin (3).
5. Connect clutch pedal position interlock switch connector (2).
6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange.
7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud.
8. Raise vehicle.

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Fig. 23: Slave Cylinder & Nuts
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not allow release lever plunger to pivot more than 2° in either
direction in the slave cylinder bore. Allowing the plunger to pivot
more than 2° in the bore will cause fluid to bypass the seal and result
in fluid leakage.

NOTE: Pull the clutch release lever toward the slave cylinder opening to insure
proper seating of the slave cylinder plunger to the release lever pocket.

9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever.
10. Install and tighten slave cylinder nuts (1) to 23 N.m (17 ft. lbs.).
11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder.

CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it
should never be disconnected.

12. Install heat shield over hydraulic line.

13. Operate linkage several times to verify proper operation.
SWITCH, CLUTCH STARTER INTERLOCK
DIAGNOSIS AND TESTING

SWITCH - CLUTCH STARTER INTERLOCK

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Fig. 24: Clutch Switch Test Point
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to
left of clutch pedal.
2. Check switch continuity with an ohmmeter while operating clutch pedal.
 Pedal Depressed - Continuity

 Pedal Released - No Continuity

3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced
separately.