Dodge Dart Forum banner
1 - 20 of 24 Posts

·
Registered
Joined
·
4 Posts
Discussion Starter · #1 ·
I have a 13 dart, ddct auto slave cylinder is leaking in the bellhousing, does anyone have a fsm link or a write up for the replacement. Also a part #? Google searches are returning very little.
124849
 

·
Administrator
Joined
·
5,738 Posts
And here I am to help. The slave cylinder also doubles as the clutch release bearing or throw out bearing. You will need to drop the trans to get to it. The Mopar part number is:
68166658AA
If you have ever dropped a Neon mtx trans, this is not much different. You should have a transmission jack and if you don't Harbor Freight does. The axle nuts are staked so you need a chisel to cut off the stakes to remove them. The lower ball joint stud to the steering knuckle is very stubborn. You will need some reverse Torx sockets. Your clutch may be soaked with brake fluid so be prepared for that. You may want to take this opportunity to get rid of the clutch delay valve and install the Deyeme racing clutch delay delete kit.


124850


124851


124852


Next post is what the FSM says.
 

·
Administrator
Joined
·
5,738 Posts
21 - Transmission and Transfer Case / Manual, C635 / Removal

1.4 L

1.Raise and support the vehicle.

2.Remove battery (Refer to 08 - Electrical/Battery System/BATTERY/Removal)
.
3.Remove the air cleaner (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner/Removal) .

4.Remove the screws from Power Distribution Center (PDC) and position it out of the way.

5.Remove bolt holding upper side of starter to transmission housing.

6.Remove lug bolts holding front wheels to the brake hubs and remove front wheels.

7.Remove left front wheel well liner.

8.Remove the belly pan. (Refer to 13 - Frame and Bumpers/Under Body Protection/BELLY PAN/Removal)

9.Drain fluid from transmission into a suitable drain pan (Refer to 21 - Transmission and Transfer Case/Manual/FLUID - Standard Procedure) .

10.Remove front closure panel air dam.

11.Remove bolt holding ground cable (2) to transmission and separate cable from transmission (1).

124853


12.Remove bolts holding lower side of battery tray to body.

13.Remove bolt holding windshield washer reservoir to the battery tray.

14.Release retainer from harness at the bottom of the battery tray.

15.Remove the left half shaft assembly from the transmission (Refer to 03 - Differential and Driveline/Half Shaft - Removal) .

16.Remove the right half shaft assembly from the transmission (Refer to 03 - Differential and Driveline/Half Shaft - Removal) .

17.Disconnect the reverse lamp sensor.

124854


18.Remove bolts holding exhaust extension pipe to manifold/catalytic converter.

19.Remove bolts holding tail pipe to the exhaust extension pipe.

20.Remove bolt holding exhaust extension pipe to engine block and separate the exhaust system from the vehicle.

21.Remove bolts holding engine/transmission mount and bracket to the body and power train and separate rear mount from the vehicle.

22.Remove the starter motor (Refer to 08 - Electrical/8F - Engine Systems/Starting/STARTER - Removal) .

23.Lower hoist so engine compartment is accessible.

24.Remove battery tray.

25.Remove bolt holding ground strap to left frame rail.

26.Pry up on the cable connector (1) to disengage both the cables from the levers and separate cables end from the shift levers.

124855


27.Disconnect the gear shift selector cables (1) at the manual levers (2).

124856


28.Disconnect the hydraulic supply pipe for the concentric slave cylinder.

124857


29.Remove bolt holding oxygen sensor wire harness to transmission housing.

30.Using a suitable hydraulic floor jack, lift and support the transmission in a stable position.

31.Remove bolts holding upper transmission to the engine block.

32.Remove bolts holding transmission upper mount (1) to the mount spacer (2) and frame rail.

124858


33.Separate the upper transmission mount (1) from the spacer (2) and the frame rail.

34.Remove bolts holding the transmission mount spacer (2) to the transmission.

35.Separate trans mount spacer (2) from the transmission (3).


36.Lower the hydraulic floor jack until the transmission rests on the support cradle load beam.

37.Raise the vehicle to gain access to the lower engine supports.

38.Using a suitable high stand, support the engine in a stable position.

39.Using a suitable transmission jack, support the transmission in a stable position and secure the transmission to the jack cradle with a safety chain or strap.

40.Remove bolts holding the left cradle extension beam to the cradle and the frame rail.

41.Separate the left cradle extension beam from the vehicle.

42.Remove bolts holding the lower transmission to the engine block.

43.Separate the transmission from the vehicle.




06 - Clutch / CYLINDER, Clutch Slave / Removal

MANUAL

WARNING:
FCA US 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: To prevent drainage of clutch master cylinder assembly upon slave cylinder removal, it is necessary to make sure brake master cylinder fluid level is full and reservoir cap is installed tight.

1.Remove transmission from vehicle. (Refer to 21 - Transmission and Transfer Case/Manual, C635 - Speed/Removal)

2.Release the retention tabs from the Concentric Slave Cylinder (CSC) (1).

124859


3.Remove the CSC bolts (2).

124860


4.Disconnect the hydraulic connection at the case. Release the retention clip (1), then separate the connection (2).

124861


5.Disconnect the hydraulic fitting (2) from the plastic retainer (1).

124862


6.Remove the CSC.
 

·
Premium Member
Joined
·
6,496 Posts
And here I am to help. The slave cylinder also doubles as the clutch release bearing or throw out bearing. You will need to drop the trans to get to it. The Mopar part number is:
68166658AA
If you have ever dropped a Neon mtx trans, this is not much different. You should have a transmission jack and if you don't Harbor Freight does. The axle nuts are staked so you need a chisel to cut off the stakes to remove them. The lower ball joint stud to the steering knuckle is very stubborn. You will need some reverse Torx sockets. Your clutch may be soaked with brake fluid so be prepared for that. You may want to take this opportunity to get rid of the clutch delay valve and install the Deyeme racing clutch delay delete kit.
That all sounds like great stuff and all, but he said it was a DDCT automatic. He may be talking about the DDCT hydraulic fluid reservoir.
 

·
Registered
Joined
·
4 Posts
Discussion Starter · #7 ·
It actually is the ddct auto trans. And it is leaking out of thw bottom of the bellhousing, which I assume means the slave cylinder failed. But info on the ddct trans is hard to find.
 

·
Administrator
Joined
·
5,738 Posts
The DDCT actually has two slave cylinders, one for the even gears and one for the odd gears. There are two different fluids in the DDCT. You should be able to figure out which is low. There is a plastic reservoir on top which has hydraulic fluid for the slave cylinders. There is gear lube inside the trans. There is a rubber plug on the side where you can check the lube inside the trans. The correct level is 1/4 inch below the fill plug. If the fluid is the hydraulic fluid coming out of the slave cylinder, you will need to drop the trans to get to the even gear slave cylinder. If the fluid is trans lube, the input shaft seal needs to be replaced and the trans needs to be removed from the car. There is a special (very expensive) tool to reset the flywheel when the trans is replaced. That usually stops people from removing their DDCT by themselves. You can take your flywheel to a dealer to do the reset and do everything else yourself.

The hydraulic fluid C SERIES DDCT SAE 75W HYDRAULIC FLUID:
Part No. 68092638AA
You need 0.9 L (0.95 qts)

Do not confuse with the C SERIES MANUAL & DUAL DRY CLUTCH
TRANSMISSION FLUID:
You need 1.66 L (1.75 qt)
Quart
Part No. 68092630AA

Gallon
Part No. 68092636AA

There are 65 steps to removing the trans from the vehicle. I will post that tomorrow. It's past 11:00 PM here.
 
  • Like
Reactions: jsblanch

·
Administrator
Joined
·
5,738 Posts
21 - Transmission and Transfer Case / Automatic - C635 DDCT / Removal

REMOVAL

NOTE:
Any time the transmission is separated from the engine you must reset the Dual Mass Flywheel before installation (Refer to 06 - Clutch/FLYWHEEL - Standard Procedure) .


1.Remove the engine cover.

2.Remove the battery (Refer to 08 - Electrical/Battery System/BATTERY/Removal) .

3.Disengage the lock (3) on the Smart Drive Unit (SDU).

124864


4.Separate the connector (2) from the SDU (1).

5.Separate the wiring harness from the battery tray.

6.Remove the Power Distribution Center (PDC) (1) and position it out of the way.

124865


7.Remove the upper battery tray bolts.

8.Raise the vehicle on a suitable hoist.

9.Remove the front wheels (Refer to 22 - Tires and Wheels/Removal) .

10.Remove the drivers side wheel house inner splash shield Refer to 23 - Body/Exterior/SHIELD, Splash, Wheel House/Removal) .

11.Remove the belly pan (Refer to 13 - Frame and Bumpers/Under Body Protection/BELLY PAN/Removal) .

12.Remove the front air dam.

13.Position a suitable drain pan under the transmission.

14.Remove the drain plug (1) from the transmission.

124866


15.Allow the fluid to drain into the drain pan (1).

124867


16.Install the drain plug (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

17.Remove bolts (1 and 2) holding lower side of battery tray to body.

124868


18.Remove bolt (1) holding windshield washer reservoir to the battery tray.

19.Release retainer from harness at the bottom of the battery tray.

20.Remove bolt holding ground cable (1) to transmission and separate cable from transmission.

21.Separate the ground cable from the side of the transmission.

124869


22.Remove the drivers side halfshaft (Refer to 03 - Differential and Driveline/Half Shaft/Removal) .

23.Remove the passenger side halfshaft (Refer to 03 - Differential and Driveline/Half Shaft/Removal) .

24.Remove the Charge Air Cooler (CAC) hose (2) from the intercooler (1).

124870


25.Remove the CAC hose nut (1) from the support bracket.

124871


26.Remove the transmission shift cable support bracket bolts.

27.Remove the lower catalytic convertor support bracket.

28.Lower the vehicle.

29.Remove the battery tray (1) from the vehicle.

124872


30.Release the locks on the wire connectors (1 and 2) at the transmission.

31.Disconnect the transmission connectors (1 and 2).

124873
 

·
Administrator
Joined
·
5,738 Posts
32.Release the connector lock (1) and disconnect the brake booster vacuum line (2).

124874


33.Remove the absolute pressure sensor wire connector (1) from the CAC (2).

124875


34.Disengage the clamp holding the vacuum hose (1) to the manifold pressure sensor (2).

124876


35.Separate the vacuum hose (1) from the manifold pressure sensor (2).

36.Remove the bolt holding the CAC hose (1) to the support bracket.

124877


37.Loosen the clamp holding the CAC hose (1) to the throttle body.

38.Separate the CAC hose (1) from the throttle body.

39.Separate the CAC (1) hose from the vehicle.

40.Remove the bolts (1) holding the upper bellhousing to the engine block adapter.

124878


41.Remove the shift cable (1) from the manual shift lever.

124879


42.Remove the transmission wiring harness from the solenoid guard bracket.

43.Disconnect the O2 sensor connectors.

44.Remove the O2 sensor wiring from the mounting bracket.

45.Using a suitable jack (1), support the transmission.

124880


46.Remove bolts (2) holding the upper transmission mount to the lower spacer.

124881


47.Remove bolts (1) holding the lower spacer to the transmission. There is two hidden bolts (1) behind the mount spacer.

48.Lower floor jack until the mount spacer is free to be removed.

49.Separate mount spacer (1) from the transmission.

124882


50.Insert a block of wood (1) between the transmission and the left cradle extension load beam (2).

124883
 

·
Administrator
Joined
·
5,738 Posts
51.Lower the transmission onto the left front cradle extension load beam (2).

52.Raise the vehicle.

53. Disconnect the wire connector from the transmission (1) fluid heater (2) .

124884


54.To add stability to the engine after transmission removal, connect a safety strap (1) from the right halfshaft bearing support mount to the bottom of the radiator support.

55.Position a suitable high-stand (3) under the engine.

124885


56.Position a suitable transmission jack (2) under the transmission.

CAUTION:
Be careful not to damage the electrical/hydraulic components when installing a safety chain to secure the transaxle to the transmission jack. If components are damaged, the transaxle must be replaced.

57.Secure the transmission to the transmission jack with a safety chain.

58.Remove the bolts holding the rear lower transmission mount (1) to the body and the transmission.

124887


59.Remove the lower rear transmission mount (1).

60.Remove center bolt holding the starter to transmission housing. Do not remove the starter.

61.Remove the left side lower cradle extension load beam (1).


124886



62.Remove two bolts (1) holding the rear lower engine spacer to the bellhousing.

124888


63.Remove two bolts (1) holding the front lower engine spacer to the bellhousing.

124889


64.Separate the transmission from the engine.

65.Lower the transmission while guiding loose components out of the way of the removal path.
 

·
Administrator
Joined
·
5,738 Posts
06 - Clutch / DISC, Clutch / Removal

DDCT

1.Remove the transmission from the vehicle (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT - Removal) .

2.Remove and discard the release bearing retaining clip (1).

124890


3.Remove the protective cap (1) .

124891


4.Remove the release bearing (1).

124892


NOTE:
Do not separate the odd gear clutch assembly.

5.Remove the odd gear clutch assembly bolts (1) and remove the clutch assembly.

124893


6.Remove the even gear clutch disc (1).

124894


7.Remove the even
gear pressure plate bolts (1) and remove the pressure plate.

124895
 

·
Administrator
Joined
·
5,738 Posts
06 - Clutch / CYLINDER, Clutch Slave / Removal

DDCT, EVEN GEARS

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.Remove transaxle from the vehicle (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT - Removal) .

2.Remove the clutch assembly (Refer to 06 - Clutch/DISC, Clutch/Removal).

3.Disconnect the hydraulic fitting from the plastic retainer (2).

124896


4.Remove the even gear slave cylinder bolts (1) and remove the slave cylinder .


Install is reverse of removal.
 

·
Administrator
Joined
·
5,738 Posts
06 - Clutch / DISC, Clutch / Installation

DDCT

1.Install the even gear pressure plate ensuring that the groove (1) of the mounting flange (1) corresponds to the oil pipe for the slave cylinder.

124897


2.Install the even gear pressure plate bolts (1) and tighten to the proper (Torque Specifications) .

124898


3.Install the even gear clutch disc (1).

124899


4.Install the odd gear clutch assembly and tighten to the proper (Torque Specifications) .

124900


5.Install the odd gear thrust bearing (1) tightening the until it touches the clutch mechanism spring tabs. Follow the adjustment procedure in (Refer to 06 - Clutch - Standard Procedure) .

124901


6.Install the protective cap (1).

124902


7.Install a NEW retention clip (1).

124903
 

·
Administrator
Joined
·
5,738 Posts
06 - Clutch / Standard Procedure

STANDARD PROCEDURE - ODD GEAR CLUTCH K1 RELEASE ROD ADJUSTMENT

CAUTION:
Be careful not to damage the electrical/hydraulic components when installing a safety chain to secure the transaxle to the transmission jack. If components are damaged, the transaxle must be replaced.

1.Position the transmission on a suitable stable work surface or transmission jack with a safety strap securing the transmission to the lift cradle.

NOTE:
The clip on the retaining cap must be broken to remove it. A NEW retaining cap has a clip attached to it.

2.Remove and discard the clip (1) holding the retaining cap to the Odd Gear Clutch K1 Release Rod adjusting nut.

124904


3.Using a pocket screw driver, pry the retaining cap from the Odd Gear Clutch K1 Release Rod adjusting nut. Save the retainer cap to use to align the adjuster nut during assembly.

124905


4.Place a straight edge (1) across the face of the bell housing (2) above the Odd Gear Clutch K1 Release Rod tip (3). Suitable clamps can be used to hold the straight edge to the bellhousing.

124906


5.Using a caliper (1), measure the distance between the bottom of the straight edge (3) down to the Odd Gear Clutch K1 Release Rod end (2).

124907


NOTE: As an alternate method, a feeler gauge can be used to perform the measurement.

6.Tighten or loosen the Odd Gear Clutch K1 Release Rod adjusting nut (2) until the Odd Gear Clutch K1 Release Rod end (2) is 2 mm (0.080 in.) to 3 mm (0.120 in.) below the bottom of the straight edge (3).

NOTE: The distance from the top of the straight edge (3) to the Odd Gear Clutch K1 Release Rod end (2) can be used if the thickness of the straight edge is subtracted from the measurement. The remainder should be 2 mm (0.080 in.) to 3 mm (0.120 in.).

7. Use the original retainer cap to check the alignment, rotate the adjuster nut a few degrees in either direction to synchronize the flats on the rod with the hex of the adjuster nut. After checking alignment, remove and discard the original retaining cap.

124908


8. Install a NEW adjuster nut retaining cap with integral clip (1).

9.Reset the dual mass flywheel (Refer to 06 - Clutch/Standard Procedure) and install the transmission in the vehicle (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Installation)

124909
.
 

·
Administrator
Joined
·
5,738 Posts
06 - Clutch / FLYWHEEL / Standard Procedure

STANDARD PROCEDURE - DUAL MASS FLYWHEEL RESET


CAUTION:
The Dual Mass Flywheel (DMF) must be reset any time the engine and transaxle are separated or damage will result on the first engine crank. Always check a new flywheel to verify it is set up properly or damage may result.

1.The Dual Mass Flywheel (DMF) (1) will appear this way once separated from the engine assembly. Note the finger position (2).

124910


2.Install the Dual Mass Flywheel Reset Tool Tool, Dual Mass Flywheel Reset 10310 to the flywheel with the set screws (1) aligned as shown over the reset fingers. When properly installed the gap (2) will be 19 - 22 mm (0.75 - 0.875 in.).

124911


NOTE: The fingers only need to be depressed to the level of the first plate. Do not depress them any further as damage may occur.

3.Turn the jack screw until the fingers align with the end of the plate (1). Tighten the set screws over both fingers until they are even with the plate.

124912


4.Loosen the jack screw and remove Dual Mass Flywheel Reset Tool Tool, Dual Mass Flywheel Reset 10310 . The flywheel will appear this way when properly reset. Note the finger position (1).

124913
 

·
Administrator
Joined
·
5,738 Posts
21 - Transmission and Transfer Case / Automatic - C635 DDCT / Installation

INSTALLATION

CAUTION:
Ensure that the transaxle bell housing and the engine block are flush before installing the bolts. Never utilize the mounting bolts to draw the transaxle to the engine.

NOTE: Any time the transmission is separated from the engine you must reset the Dual Mass Flywheel .

1.Verify that the dual mass flywheel has been properly set (Refer to 06 - Clutch/FLYWHEEL - Standard Procedure) .

2.Verify that the transaxle is in neutral and the clutch can rotate freely.

3.With the engine properly supported on a high-stand (3) and secured with a safety strap (1), raise the transaxle (2) up into the engine compartment while guiding loose components out of the installation path.

124914


4.Align the clutch release bearing on the transaxle into the Dual Mass Flywheel (DMF).

5.Push transaxle toward the engine until the bellhousing butts against the engine block spacer. If necessary, adjust the tilt mechanism on the transmission jack to achieve proper alignment.

NOTE: If the bellhousing will not butt up against the engine block spacer, do not use a bolt to draw them together.

124915


NOTE: If the transaxle bellhousing will not butt against the back of the engine block and the DMF was properly set, rotate the crankshaft until the clutch lugs engage into the DMF.

6.Hold the transaxle against the engine block spacer and Install the front lower bellhousing bolts (1) (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

124916


7.Hold the transaxle against the engine block spacer and Install the rear lower bellhousing bolts (1) (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

124917



8. Raise the transaxle up to gain clearance to install cradle extension load beam.

9.Install the left side lower cradle extension load beam (1).

124918


10.Install center bolt to hold the starter to transaxle housing (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

11.Install the lower rear transmission mount (1).

12.Install the bolts to hold the rear lower transaxle mount (1) to the body and the transaxle (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

124919


13.Remove the safety strap (1) from between the right halfshaft bearing support mount and the bottom of the radiator support.

14.Lower and remove the high-stand (3) from under the engine.

15.Remove the safety chain holding the transaxle to the transmission jack (2).

124920


16.Place a wooden block (1) between the cradle extension load beam (2) and the transaxle.

124921


17.Lower and remove the transmission jack from under the transaxle.

18.Connect the wire connector to the transaxle (1) fluid heater (2) .

124922


19.Lower the vehicle.

20.Using a suitable floor jack (1), raise the transmission up and off the left front cradle extension load beam.

124923


21.Remove the wood block from the cradle extension load beam.
 

·
Administrator
Joined
·
5,738 Posts
22.Place the mount spacer (1) in position on the transaxle.

124924


23.Raise the floor jack until the mount spacer bolts locations (1 and 2) line up.

24.Install the bolts (1) to hold the lower spacer to the transaxle. There is two hidden bolts (1) behind the mount spacer (Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

25.Install the bolts (2) to hold the upper transaxle mount to the lower spacer(Refer to 21 - Transmission and Transfer Case/Automatic - C635 DDCT/Specifications) .

124925


26.Lower and remove the floor jack from under the transaxle.

27.Install the O2 sensor wiring on the mounting bracket.

28.Connect the O2 sensor connectors.

29.Install the transmission wiring harness onto the solenoid guard bracket.

30.Install the shift cable (1) onto the manual shift lever.

124926


31. Install the bolts (1) to hold the upper bellhousing to engine block adapter.

124927


32.Place the CAC (1) hose in position between the intercooler and the throttle body.

33.Connect the CAC hose (1) onto the throttle body.

34.Tighten the clamp to hold the CAC hose (1) to the throttle body.

35.Install the bolt to hold the CAC hose (1) to the support bracket.

124928


36.Connect the vacuum hose (1) to the manifold pressure sensor (2).

37.Engage the clamp holding the vacuum hose (1) to the manifold pressure sensor (2).

124929


38.Connect the absolute pressure sensor wire connector (1) to the CAC (2).

124930


39.Connect the brake booster vacuum line (2) and engage the connector lock (1).

124931


40.Connect the transaxle connectors (1 and 2).

41.Engage the locks on the wire connectors (1 and 2) on the transaxle.

124932


42.Install the battery tray (1) in position on the vehicle.

124933


43.Raise the vehicle.

44.Install the lower catalytic convertor support bracket.

45.Install the transmission shift cable support bracket bolts.
 
1 - 20 of 24 Posts
Top