Description

Chrysler NS, GS Service Manual – Clutch System Factory Documentation

If you’ve ever fought a clutch that won’t release or a pedal that feels dead, you know the frustration of aftermarket instructions that skip the critical specs. Chrysler designed the NS and GS with two different clutch setups — a modular assembly for the 2.0L and 2.4L gasoline engines and a conventional pressure plate for the 2.5L diesel. Mixing up the disc diameter won’t cause damage because they’re both 240 mm, but the parts don’t interchange. The factory Chrysler NS, GS Service Manual gives you the exact application data, removal procedures, and torque specs in just 18 pages dedicated to the clutch system. No fluff, no copy-paste from a generic manual.

Clutch Disc and Cover Application – Gasoline vs Diesel

Page 1 of this document tells you which clutch goes where. The 2.0L and 2.4L gasoline engines use a modular clutch assembly — a single dry disc that comes as a unit with the cover. The 2.5L diesel uses a conventional disc and pressure plate that you can service separately. Both are 9.5 inches, but the splines, pilot bearing, and release bearing differ. This manual breaks down the identification so you don’t order the wrong part for your specific Chrysler NS or GS. Manual Transmission removal is required to access the clutch, and the manual lists the steps in order.

Clutch Diagnosis: Grab, Chatter, Slips – Service Diagnosis Charts

You can waste hours chasing a chatter that’s really drive plate misalignment or a slip caused by oil contamination. The manual includes multiple service diagnosis tables: grab/chatter, slips, improper release, pedal noise, and clash-into-reverse. There’s also a clutch pedal position switch electrical test (yes, Electrical is covered) with a mechanical test first. Page 3 walks you through the switch testing. If you’re chasing a no-start condition from a bad clutch switch, this section saves you from throwing parts at it. Chrysler NS GS Wiring Diagram complements this manual for full electrical troubleshooting.

Modular Clutch Assembly Removal (2.0L and 2.4L Gasoline)

Removing the modular clutch requires transaxle removal first. The manual covers the step-by-step removal and installation, including alignment of the clutch disc. It lists the required tools: a clutch alignment tool (special tool number provided), a socket set, and a torque wrench capable of foot-pounds. The installation section specifies tightening the pressure plate bolts in a star pattern to the factory spec. No shortcuts — the factory document insists on the correct procedure to avoid warping the cover. Page 9 begins the modular clutch section.

Clutch Cable Adjustment and Self-Adjuster Function Check

The clutch cable in these Chrysler vehicles has a built-in self-adjuster mechanism. The manual clearly states that the cable requires no maintenance or lubrication, but it does include a function check procedure on page 18. To verify the adjuster is working, you depress the pedal to the floor and release it, then measure free play. If the adjuster is stuck, you’ll need to replace the cable assembly — there are no serviceable parts. This section saves you from trying to lubricate a cable that’s sealed from the factory.

Clutch Tightening Reference – OEM Torque Specifications

Torque specs live on page 18 under “CLUTCH TIGHTENING REFERENCE.” You’ll find the values for the pressure plate bolts, flywheel bolts, and release bearing fork pivot. These are not generic numbers — they come from Chrysler engineering for the NS and GS. Using the wrong torque can cause a bolt to back out or strip the threads in the flywheel. The manual also reminds you to check the runout of the clutch cover and disc if you’re reinstalling the original parts. Manual Transmission removal is a prerequisite for any clutch work, and the spec table gives you the critical numbers to finish the job.

Source Validity – Factory OEM vs Aftermarket

This document is a direct scan of the Chrysler-issued service manual for the NS and GS models. It’s not a third-party rewrite or a compilation of forum tips. Every torque spec, every diagnosis chart, every removal step comes from the same binder that dealership techs used. When you’re working on a 2.5L diesel clutch assembly or the modular unit, you want the official tightening references — not something published by a company that never held a wrench. Chrysler NS/GS Transaxle and Power Transfer Unit Service Manual – Section: Power covers the transmission removal in detail if you need that separate document.

FAQ

Does this manual cover the electrical testing of the clutch pedal position switch?

Yes, it includes both mechanical and electrical test procedures.

What tools are required for the clutch replacement procedure on the 2.4L gasoline engine?

According to the manual, you’ll need a clutch alignment tool (Chrysler special tool 6786 or equivalent), a 3/8-inch drive torque wrench reading in foot-pounds, a socket set including E12 Torx and 13mm, a transmission jack for transaxle removal, and a dial indicator to check runout if reusing the clutch cover. The manual also specifies a micrometer for measuring clutch disc thickness. All measurements are in imperial units. Safety stands and eye protection are mandatory — the manual includes a warning about clutch dust containing asbestos.

You’re looking at 18 pages of factory-authorized data for the Chrysler NS and GS clutch system. Whether you need to diagnose a chatter, swap the modular unit, or torque the pressure plate to spec, this document gives you the numbers and steps that the dealership uses. Chrysler NS GS Tires & Wheels Service Manual is available separately if you’re rotating tires or replacing wheel bearings. Access the Factory Manual and get back to work without the guesswork.