DodgeRam.info > TSB's > 21-004-02

TSB 21-004-02

3.7L, 4.7L, and 5.7L Clutch Housing and Structural Cover Installation

Visit Geno's Garage for Truck accessories.

Date: Dec. 13, 2002

Models: 2002 - 2003 (DR) Ram Pickup

2000 - 2003 (AN) Dakota
2002 - 2003 (DR) Ram Pickup

NOTE: THIS BULLETIN APPLIES TO 2000 - 2003 (AN) DAKOTA TRUCKS EQUIPPED WITH A 4.7L ENGINE (SALES CODE EVA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36). 2002 - 2003 (DR) RAM TRUCK EQUIPPED WITH 3.7L, 4.7L OR 5.7L ENGINE (SALES CODE EKG, EVA, OR EZA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36, A64, OR A74).

Discussion:
The clutch housing maintains alignment between the crankshaft and transmission input shaft. The structural cover provides additional powertrain stiffness and reduces noise and vibration. If either one is bolted to the engine or to each other, in the wrong sequence, drivetrain misalignment could result. Misalignment could result in reduced life expectancy of drivetrain components such as the clutch disc assembly, pilot bearing, clutch release components, and transmission.

If misalignment is suspected and the clutch housing bore runout is found to be excessive using the diagnostic procedures in the service manual or if the clutch housing and structural cover has been removed for any reason, the components should be installed using the following Repair Procedure.

Equipment Required:

Heat Gun

Pentastar Service Equipment (PSE) W-PH1200 or equivalent

Repair Procedure: 

1.	Open the hood.
2.	Disconnect the negative battery cable.
3.	Remove the transmission as outlined in the service information available in MDS2 or the 2003 DR Ram Truck Service Manual (Publication No. 81-370–03059) page 21–43 (5.7L only).
4.	Clean the clutch housing mounting surface of the engine block using Mopar Engine Degreaser p/n 04318040 (or equivalent).
5.	Verify that the clutch housing alignment dowels are in good condition and properly seated.
CAUTION: THE STRUCTURAL COVER MUST BE INSTALLED AS DESCRIBED IN THE FOLLOWING STEPS. FAILURE TO DO SO WILL CAUSE SEVERE DAMAGE TO THE COVER, AND ENGINE NOISE.
		FIGURE 1 - STRUCTURAL COVER MANUAL TRANSMISSION 1 -  Structural Cover 2 - 10 mm Bolt - Passenger Side Front 3 - 10 mm Bolt - To Clutch Housing 4 - 10 mm Bolt - Passenger Side Rear 5 - 10 mm Bolt - Driver Side Front 6 - 10 mm Bolt - Driver Side Rear 7 - 10 mm Bolt - To Clutch Housing
6.	Align and install the clutch housing and the structural cover on the back of the block in the following sequence:
	a.	Install four (4) clutch housing to engine (3/8 in. diameter) bolts located at the top of the clutch housing and torque to 40.6 Nm (30 lb ft).
	b.	Install dust shield (1/4 in. diameter) bolt and torque to 4.5 Nm (40 in. lbs.).
	c.	Position structural cover flush to the engine block and the clutch housing, and hold in position while hand starting the fasteners.
	CAUTION: THE STRUCTURAL COVER MUST BE HELD TIGHTLY AGAINST THE CORNER FORMED BY THE ENGINE AND THE TRANSMISSION CLUTCH HOUSING DURING TIGHTENING SEQUENCE. FAILURE TO DO SO MAY CAUSE DAMAGE TO THE COVER AND ENGINE NOISE.
	d.	Tighten two (2) structural cover fasteners (Item 3 & 7) (Figure 1) to the clutch housing and torque to 5 – 11 Nm (50-100 in. lbs).
	e.	Install four (4) structural cover fasteners (Items 2,4,5, & 6) (Figure 1) to the engine and torque to 5 – 11 Nm (50-100 in. lbs).
8.	Install the (2 - 5.7L) (4 - 3.7L & 4.7L) engine to housing bolts (7/16 in. diameter bolts) and torque to 68 Nm (50 ft. lbs.), as a last step.
9.	Install transmission (5.7L only) and transfer case if equipped.
NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK WHEN THE PROCEDURE IS COMPLETE.
10.	Reconnect the negative battery cable.

Policy:    Information Only.

This page was edited on: May 3, 2004