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TSB 06-03-89

Clutch Housing, Pilot Bore Runout & Face Squareness Adjustment

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Date: June 12, 1989

Models: 1987 -1989 AD - Dodge Ram Pickup/Ram Charger

B/AB - DODGE RAM VAN/WAGON (REAR-WHEEL-DRIVE)
D/AD - DODGE RAM PICKUP/RAMCHARGER SPORT UTILITY (RDW, 4WD)
N/AN - DODGE DAKOTA/DAKOTA SPORT (RWD, 4WD)

1987-89 B/AB, D/AD & N/AN Bodies Equipped With NP2500, NP435 And A833 Manual Transmission

Symptom/Condition:

Some rear wheel drive/four wheel drive vehicles may exhibit one or more of the following symptoms/conditions; high shift effort, clutch drag, clutch chatter, noisy or excessively worn main drive pinion (input shaft) bearings and worn pilot bushing.

These symptoms/conditions may be caused by a misaligned clutch housing.

The following procedure should be performed whenever a diagnosis/inspection does not reveal an obvious problem in the clutch and/or transmission systems.

NOTE: CLUTCH HOUSING MISALIGNMENT SHOULD BE SUSPECT ON VEHICLES WITH VERY LOW MILEAGE OR VEHICLES WHICH HAVE RECENTLY HAD THE CLUTCH HOUSING REMOVED FOR ENGINE OR TRANSMISSION SERVICE.

Tools Required:

1 - Dial Indicator and Clamp
1- M10 x 1.0 Threaded Rod - 10" Long -- Use on 2.2L/2.5L Engines
1 - M10 x 1.0 Lock Nut
1- 7/16" x 20 Threaded Rod - 10" Long -- Use on 3.9L/5.2L /5.9L Engines
1- 7/16" x 20 Lock Nut

Parts Required:

2.2L/2.5L Engines

2 - offset Dowels (.007 Offset)         PN 4536315
2 - offset Dowels (.014 Offset)         PN 4536316
2 - offset Dowels (.021 Offset)         PN 4536317

3.9L/5.2L/5.9L Engines

2 - Offset Dowels (.007 Offset)        PN 1736347
2 - Offset Dowels (.014 Offset)        PN 1736348
2 - Offset Dowels (.021 Offset)        PN 1736353

Diagnosis:

This procedure involves mounting a dial indicator on the engine and checking clutch housing pilot bore and mounting face alignment.

1. Remove the clutch housing and any housing to engine struts.

2. Remove the clutch plate and disc from the flywheel.

3. Remove the clutch release fork from the housing.

4. Thoroughly clean the clutch housing and engine block mounting faces. They must be free of all dirt, oil and corrosion.

5. Remove one (1) flywheel mounting bolt. In its place, install the appropriate threaded rod and lock nut (Figure 1). Be sure to tighten the lock nut to assure a rigid support for the dial indicator.

Figure 1

6. install the clutch housing and tighten the bolts to the following torque values.

3/8" diameter bolt        30 ft-lbs (41 N-m)
7/16" diameter bolt      50 ft-lbs (68 NM)
12 mm diameter bolt    70 ft-lbs (95 NM)

NOTE: THE ORDER IN WHICH THE CLUTCH HOUSING TO ENGINE BOLTS ARE TIGHTENED WILL AFFECT PILOT BORE RUNOUT, ALWAYS TIGHTEN THE BOLTS NEAREST THE ENGINE DOWELS FIRST.

7. Mount the dial indicator (on the threaded -rod) in the clutch housing pilot bore as shown in Figure 2. Make sure the dial indicator stylet (probe) is square to the bore.

8. Rotate the engine until the dial indicator stylet is at the top of the clutch housing pilot bore and zero the indicator.

9. Rotate the engine at 45° increments and record the eight (8) indicator readings. The recorded readings should appear similar to the example shown in Figure 3.

NOTE , PERFORM THIS STEP AT LEAST TWO (2) TIMES TO BE SURE THAT THE RESULTS ARE REPEATABLE.

 

CLUTCH HOUSING PILOT BORE RUNOUT SUBTRACT BEACH INDICATOR READING FROM THE READING ON THE OPPOSITE SIDE OF THE PILOT BORE TO DETERMINE THE MAGNITUDE AND DIRECTION OF THE RUNOUT.
EXAMPLE (P - POSITION) (P1)    .000" - (P5) (-.007.) = .007" (P2) + .002" - (P6) (-.010") = .012" (P3) + .004" - (P7) (-.005") = .009" (P4)  - .001" - (P8) (+.001") =  - .002" (= .002")
THE LARGEST DIFFERENCE IS .012" AND IS CALLED TOTAL INDICATOR READING (TIR). IN THIS EXAMPLE, THE CLUTCH HOUSING PILOT BORE IS OFFSET FROM THE CENTERLINE OF THE CRANKSHAFT BY .006" (ONE HALF OF THE .012" TIR). WHEN THE TIR IS .010" OR LESS, THE CLUTCH HOUSING PILOT BORE RUNOUT IS WITHIN SPECIFICATION AND NO ADJUSTMENT IS REQUIRED. WHEN THE TIR EXCEEDS .010"', OFFSET DOWELS MUST BE INSTALLED TO BRING THE RUNOUT WITHIN SPECIFICATION AS OUTLINED IN STEP 1. CLUTCH HOUSING PILOT BORE RUNOUT ADJUSTMENT IN THE REPAIR PROCEDURE. NOTE: THE DIAL INDICATOR READS (+) POSITIVE WHEN THE SLTYLET IS DEPRESSED AND NEGATIVE WHEN THE STYLET IS EXTENDED- IN THIS EXAMPLE, THE DIRECTION OF OFFSET IS TOWARD THE -.010" READING.
Figure 3

10. Reposition the dial indicator so that the stylet is square to the rear face of the clutch housing on the rim of the pilot bore (Figure 4).

11. Rotate the engine until the dial indicator stylet is at the 10 o'clock position and zero the indicator.

CAUTION: CRANKSHAFT END PLAY MAY INFLUENCE THE DIAL INDICATOR READINGS. BEFORE ZEROING THE INDICATOR PUSH THE CRANKSHAFT REARWARD

12. Rotate the engine at 90° increments and record the four (4) indicator readings. The recorded reading should appear similar to the example shown in Figure 5.

NOTE: PERFORM THIS STEP AT LEAST TWO (2) TIMES TO BE SURE THAT THE RESULTS ARE REPEATABLE.

 

CLUTCH HOUSING FACE SQUARENESS SUBTRACT THE LOWEST (-) VALUE FROM THE HIGHEST (+) VALUE TO DETERMINE THE FACE SQUARENESS.
EXAMPLE (P - POSITION) (P4) + .009" - (P3) (-.004") - .0130 TIR
WHEN THE FACE SQUARENESS EXCEEDS .010" TIR, METAL SPACERS MUST BE FABRICATED OUT OF THE APPROPRIATE THICKNESS SHIM STOCK TO SQUARE THE TRANSMISSION FACE WITH THE ENGINE FACE. TO DETERMINE SPACER THICKNESS, SUBTRACT THE LOWEST INDICATOR READINGS FROM THE HIGHEST READING. EXAMPLE (P4) + .009" - (P1) (-.000") = .009" SPACER TO BE LOCATED AT P1 (P4) + .009" - (P2) (-.003") - .012" SPACER TO BE LOCATED AT P2 (P4) + .009" - (P3) (-.004") - .013" SPACER TO BE LOCATED AT P3
Figure 5

13. If either the clutch housing pilot bore runout or face squareness exceeds .01011 TIR perform the following repair procedure as required. If the pilot bore runout and face squareness are .010" TIR or less, the clutch housing is within specification and no adjustment is required.

Repair Procedure:

This procedure involves installation of offset dowels and/or metal spacers to adjust the clutch housing alignment.

Clutch Housing Pilot Bore Runout Adjustment

1.    Remove clutch housing and the two (2) original engine dowels.

2. Based on the TIR value select the appropriate pair of offset dowels from the chart below.

TIR VALUE	2.2L/2.5L DOWEL PIN	3.9L/5.2L/5.9L DOWEL PIN	Dowel Offset
.011" to .021"	4536315	1736347	.007"
.022" to .035"	4536316	1736348	.014"
.036" to .052"	4536317	1736353	.021"

NOTE: WHEN THE TIR VALUE IS GREATER THAN .052" THE CLUTCH HOUSING MUST BE REPLACED AND THE RUNOUT CHECKED ON THE NEW CLUTCH HOUSING.

3. Using a soft faced hammer install both offset dowels with the offset position in the direction that will counter the pilot bore offset.

NOTE: THE SLOTTED SIDE OF THE DOWELS MUST POINT AWAY FROM THE ENGINE.

4. Install the clutch housing, starting at the bolts closest to the dowels tighten the bolts to the following torques.

3/8" diameter bolt       30 ft-lbs (41 NM)
7/16" diameter bolt     50 ft-lbs (68 NM)
12 mm diameter bolt   70 ft-lbs (95 NM)

5. Remeasure clutch housing pilot bore runout. If runout is .010" or less proceed to Step 1 - Clutch Housing Face Squareness Adjustment. If runout exceeds .010" loosen clutch housing bolts, using a large screwdriver rotate dowels in the direction that will counter the pilot bore offset, torque the bolts and remeasure clutch housing pilot bore runout.

Clutch Housing Face Squareness Adjustment

1. Based on the face squareness TIR value fabricate spacers out of appropriate thickness shim stock as shown in Figure 6. Mark each spacer location so that the spacer can be correctly positioned between the transmission and clutch housing during final assembly.

2. Remove dial indicator, clutch housing and threaded rod. Install and tighten the flywheel bolt to one of the following torques.

2.2L/2.5L Engine               70 ft.-lbs. (95 NM)
3.9L/5.2L/5.9L Engine      55 ft.-lbs. (75 NM)

3. Thoroughly clean the input shaft clutch splines and clutch disc splines. They must be free of any dirt or rust. Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the input shaft splines. Be sure all excessive grease is removed.

4. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing. Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing.

5. Install clutch disc and cover, release fork and release bearing.

6. Install clutch housing. Starting at the bolts closest to the dowels tighten the bolts to the following torques.

3/8" diameter bolt               30 ft-lbs (41 NM)
7/16" diameter bolt             50 ft-lbs (68 N,m)
12 mm diameter bolt           70 ft-lbs (95 NM)

Install the clutch housing to engine struts (if any). Tighten the strut to clutch housing bolts first, and then the strut to engine bolts to the above torque values.

7. Install the transmission. Be sure to locate the fabricated spacers in the correct positions (Figure 7).

Notes:

POLICY:     Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No.       06-10-01-90 . . . . . . . . . . . . . 3.5 Hrs.
         NOTE: THIS OPERATION DOES NOT INCLUDE TRANSMISSION - REMOVE AND INSTALL.

FAILURE CODE: 64 - Misaligned or Mismatched