CLUTCH Clutch System FIAT 500
CLUTCH Clutch System FIAT 500
CLUTCH Clutch System FIAT 500
2012 CLUTCH
DESCRIPTION
DESCRIPTION
Fig. 1: Clutch Master Cylinder, Slave Cylinder & Interconnecting Hydraulic Line
Courtesy of CHRYSLER GROUP, LLC
The typical clutch hydraulic system consists of a clutch master cylinder (3), slave cylinder (1), and an
interconnecting hydraulic line (2). Clutch hydraulic fluid is supplied by the brake system via the brake master
cylinder reservoir.
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: Under normal operating conditions, the clutch hydraulic system does not
require additional fluid for the life of the vehicle. Since the clutch shares the
brake reservoir, the fluid level will be maintained whenever the brake system is
checked.
The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications. No
other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only MOPAR®
brake fluid or equivalent from a tightly sealed container.
MANUAL
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OPERATION
OPERATION
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 release bearing which is
in contact with the pressure plate diaphragm spring. As additional force is applied, the bearing depresses the
diaphragm spring fingers inward on the fulcrums. The action moves the pressure plate rearward, relieving
clamping force on the clutch disc.
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.
CLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING Oil leak at engine rear main or Correct leak and replace modular clutch
COVERED WITH OIL OR transaxle input shaft seal. assembly.
GREASE
Too much grease applied to Apply lighter coating of grease to splines.
splines of disc and input shaft.
PARTIAL Clutch cover, spring, or Replace clutch assembly.
ENGAGEMENT OF release fingers bent, distorted
CLUTCH DISC (rough handling, improper
assembly).
Clutch disc damaged or Replace clutch assembly.
distorted.
Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
Clutch Misalignment
engine dowels and dowel holes for damage.
Correct as necessary.
CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT Normal wear. Replace clutch assembly.
Driver frequently rides Replace clutch assembly.
(slips) clutch, results in
MANUAL
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STANDARD PROCEDURE
STANDARD PROCEDURE - BLEEDING CLUTCH HYDRAULIC CIRCUIT
1. Use Mopar brake fluid, or an equivalent quality fluid meeting DOT 3 standards only. Use fresh, clean
fluid from a sealed container at all times.
2. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank
manufacturers pressure recommendations. The service filling machine should be pressurized between 2.0
and 2.5 bar (29 - 36 PSI).
3. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding.
MANUAL
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4. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or
drawing air back into the system.
5. Remove dust cap from bleeder valve and connect the transparent bleeder hose to bleeder valve.
NOTE: Use a container to capture hydraulic fluid and a transparent bleeder hose
to route fluid to the container.
NOTE: The container must be at a lower level than the bleeder valve on the clutch
slave cylinder.
6. Place the other end of hose in the bleeder container to capture the used fluid. The end of the hose MUST
be submerged in the DOT 3 brake fluid.
7. Turn on the service filling machine.
NOTE: While bleeding the system, do not allow the clutch fluid reservoir to
completely empty out. If this happens, refill the clutch fluid reservoir, and
repeat the procedure.
8. Open the bleeder valve on the clutch slave cylinder enough to allow fluid to flow from the clutch
hydraulic system.
9. Allow fluid to flow out of bleed port until no more air bubbles can be seen in the transparent bleeder
hose.
10. Once fluid is free of air bubbles; make 15 quick actuations between clutch pedal stop positions.
11. Close the bleeder valve at the clutch slave cylinder and disconnect the service filling machine.
12. Check clutch pedal to see if vehicle is properly bled.
13. If vehicle is not properly bled, repeat procedure.
14. Remove bleeder cap from the clutch fluid reservoir and replace reservoir cap.
15. Disconnect transparent bleeder hose from bleeder valve and replace dust cap.
1. Verify fluid level in clutch/brake cylinder. Top off with DOT 3 brake fluid as necessary. Leave cap off.
NOTE: The container must be positioned at a lower level than the bleeder valve
on the clutch slave cylinder
2. Install suitable size and length of clear hose to the bleeder port (1) in order to monitor and divert fluid into
a suitable container.
3. Have the assistant press down and hold the clutch pedal until it reaches the floor.
MANUAL
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NOTE: Do not allow clutch/brake fluid reservoir to run dry while fluid exits bleed
port. If the reservoir runs dry during this procedure, it must be refilled. and
this step must be repeated.
NOTE: Ensure the assistant does not release the clutch pedal from the floor while
the bleed port on the clutch slave cylinder is open. Otherwise, air will enter
the clutch hydraulic circuit.
4. Open the bleed port on the clutch slave cylinder enough to allow hydraulic fluid to drain. Any air in the
system will escape at this time.
5. Close the bleed port on the clutch slave cylinder, and have the assistant release the clutch pedal to the full
up position.
6. Repeat steps 5 through 7 at least 15 times or until air bubbles are no longer present in the clutch hydraulic
fluid.
7. Slowly actuate the clutch pedal 10 times between the full up and pedal stop position.
8. Apply parking brake . Start engine and verify clutch operation and pedal feel. If the clutch pedal feels
fine and the transaxle can be easily shifted from neutral to any gear, the clutch is operating correctly. If
pedal still feels spongy or clutch does not fully disengage, excessive air is still trapped within the system,
most likely at the master cylinder.
9. Disconnect the hose from the bleed port on the clutch slave cylinder.
10. Top off brake master cylinder fluid level with DOT 3 brake fluid as necessary.
SPECIFICATIONS
SPECIFICATIONS
SPECIAL TOOLS
SPECIAL TOOLS
MANUAL
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REMOVAL
Fig. 3: Bearing
Courtesy of CHRYSLER GROUP, LLC
INSTALLATION
INSTALLATION
MANUAL
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Fig. 4: Bearing
Courtesy of CHRYSLER GROUP, LLC
NOTE: Verify that the release bearing is snapped into the release fork and not sitting
on top of it.
1. Lubricate the crankshaft pilot bearing and the input shaft splines with Mopar® high temperature bearing
grease or equivalent.
2. Install the new release bearing (1) and secure to the release fork.
3. Ensure that the release fork fingers (1) and the retention tabs (2) on the release bearing are correctly
oriented.
MANUAL
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4. Install the transmission. Refer to INSTALLATION (CODE EAF) and INSTALLATION (CODE
EAB)
REMOVAL
2. Disconnect the high pressure line from the master cylinder and plug both openings.
3. Lower the vehicle.
4. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL .
MANUAL
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5. Remove the supply hose from the brake master cylinder and plug both openings.
6. Remove the instrument panel reinforcement. Refer to PANEL, INSTRUMENT, REMOVAL .
7. Disconnect the clutch start (1) and brake lamp switches (2).
MANUAL
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INSTALLATION
INSTALLATION
Fig. 10: Brake Pedal, Brake Master Cylinder & Mounting Nuts
Courtesy of CHRYSLER GROUP, LLC
1. Install the pedal assembly to the vehicle, tighten the mounting nuts to 16 N.m (12 lb. ft.).
2. Connect the brake pedal to the brake master cylinder push rod.
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3. Connect the clutch start (1) and brake lamp switches (2).
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REMOVAL
MANUAL
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INSTALLATION
INSTALLATION
3. Install the hydraulic line to the slave cylinder. Install the clip (3).
4. Bleed the hydraulic system. Refer to STANDARD PROCEDURE.
5. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
DISC, CLUTCH
REMOVAL
REMOVAL
MANUAL
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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
INSTALLATION
INSTALLATION
MANUAL
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WARNING: Chrysler LLC 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.
NOTE: Ensure that the clutch disk is properly centered as transaxle installation could
be difficult.
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary.
2. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have
been removed.
3. Insert a suitable clutch alignment tool into the pilot of the crankshaft flange.
4. Position the clutch disc to the flywheel.
5. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the new pressure plate-
to-flywheel bolts.
6. Tighten pressure plate bolts evenly and in rotation a few threads at a time.
7. Using a "star" pattern, torque pressure plate bolts to 16 N.m (12 ft. lbs.). Remove the clutch alignment
tool.
CAUTION: Do not over lubricate shaft splines. This will result in grease
contamination of disc.
MANUAL
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8. Apply light coat of MOPAR® High Temperature Bearing Grease or equivalent to clutch disc hub and
splines of transmission input shaft.
9. Install transaxle Refer to INSTALLATION INSTALLATION .
FLYWHEEL
OPERATION
OPERATION
The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the
rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain.
The crankshaft has the tendency to attempt to speed up and slow down in response to the cylinder firing pulses.
The flywheel dampens these impulses by absorbing energy when the crankshaft speeds and releasing the energy
back into the system when the crankshaft slows down.
REMOVAL
REMOVAL
WARNING: Chrysler LLC 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.
MANUAL
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2. Install Flywheel Locking Tool (special tool #10272, Tool, Flywheel Locking).
3. Remove clutch pressure plate and disc. Refer to DISC, CLUTCH, REMOVAL.
4. Remove the flywheel-to-crankshaft bolts (1) and remove the flywheel assembly.
INSTALLATION
INSTALLATION
WARNING: Chrysler LLC 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.
1. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have
been removed.
2. Install Flywheel Locking Tool (special tool #10272, Tool, Flywheel Locking).
3. Install the flywheel-to-crankshaft bolts using a star pattern. Tighten to 15 N.m (11 ft.lbs.). Using a star
pattern, tighten the bolts an additional 40 degrees.
4. Install clutch pressure plate and disc. Refer to DISC, CLUTCH, INSTALLATION.
5. Install transaxle assembly. Refer to INSTALLATION INSTALLATION .
REMOVAL
MANUAL
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2. Disconnect the supply pipe from the master cylinder and plug both openings.
3. Lower the vehicle.
4. Remove the battery tray Refer to TRAY, BATTERY, REMOVAL .
5. Remove the supply hose from the brake master cylinder and plug both openings.
6. Remove the instrument panel reinforcement. Refer to PANEL, INSTRUMENT, REMOVAL .
MANUAL
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7. Disconnect the clutch start (1) and brake lamp switches (2).
Fig. 25: Brake Pedal, Brake Master Cylinder & Mounting Nuts
Courtesy of CHRYSLER GROUP, LLC
INSTALLATION
INSTALLATION
MANUAL
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Fig. 26: Brake Pedal, Brake Master Cylinder & Mounting Nuts
Courtesy of CHRYSLER GROUP, LLC
1. Install the pedal assembly to the vehicle, tighten the mounting nuts to 16 N.m (12 ft. lbs.).
2. Connect the brake pedal to the brake master cylinder push rod.
3. Connect the clutch start (1) and brake lamp switches (2).
MANUAL
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REMOVAL
1. Remove the pedal bracket assembly from the vehicle and place on a bench. Refer to PEDAL AND PAD,
CLUTCH, REMOVAL.
2. Depress and hold the clutch pedal to allow access to the external sensor lever (1).
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4. Swing the lever (1) up until it snaps into place, release the clutch pedal.
5. Carefully pull up on the retention lever (1) to unlock the rivet from the pedal assembly.
MANUAL
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6. Disengage the locating tab (1) from the pedal assembly and remove the switch.
INSTALLATION
INSTALLATION
1. Engage the locating tab (1) to the pedal assembly and install the switch.
MANUAL
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NOTE: If the either retaining feature on the switch will not securely hold the lever
in place replace the switch.
2. Snap the rivet (2) in place by pushing down, lock the switch in place by rotating the lever (1) until it
snaps in place.
3. Swing the external lever into place making sure that the stud on the pedal is captured.
MANUAL
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5. With the switch fully locked in place, cycle the clutch pedal several times to verify proper installation.
6. Install the pedal assembly into the vehicle Refer to PEDAL AND PAD, CLUTCH, INSTALLATION.
MANUAL
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