Dodge Neon / Neon SRT-4. Manual — part 56

SPECIAL TOOLS

CLUTCH INTERLOCK/UPSTOP
SWITCH

DESCRIPTION

LHD

The LHD clutch interlock/upstop switch is an

assembly consisting of two switches: an engine
starter inhibit switch (interlock) and a clutch pedal
upstop switch (Fig. 6). The switch assembly is located
in the clutch/brake pedal bracket assembly (Fig. 7),
each switch being fastened by four plastic wing tabs.

RHD

The RHD clutch interlock/upstop switch (Fig. 8)

consists of a single, multi-function switch that is acti-
vated by hydraulic clutch master cylinder push rod
travel.

Tool, Clutch Line Disconnect - 6638A

Fig. 6 Clutch Interlock/Upstop Switch

1 - UPSTOP SWITCH
2 - INTERLOCK SWITCH
3 - CONNECTOR

Fig. 7 Clutch/Brake Pedal Bracket Assembly

1 - UPSTOP SWITCH
2 - INTERLOCK SWITCH
3 - CLUTCH PEDAL
4 - CONNECTOR

Fig. 8 Clutch Interlock/Upstop Switch

1 - INTERLOCK/UPSTOP SWITCH
2 - MASTER CYLINDER
3 - CONNECTOR

6 - 8

CLUTCH

PL/SRT-4

CLUTCH (Continued)

OPERATION

CLUTCH INTERLOCK SWITCH

The clutch interlock switch prevents engine starter

operation and inadvertent vehicle movement with the
clutch pedal in the up position (not depressed), or
under normal conditions with the clutch engaged and
the transaxle in gear.

WARNING: WHEN THERE IS A LOSS OF CLUTCH
SYSTEM HYDRAULIC FLUID, OR THE CLUTCH
MASTER CYLINDER PUSHROD IS DISCONNECTED
FROM THE PEDAL LEVER, THE ENGINE MAY
START WITH THE CLUTCH ENGAGED, CAUSING
UNDESIRABLE

VEHICLE

MOVEMENT

IF

THE

TRANSAXLE IS IN ANY GEAR.

The switch is open while the clutch pedal is at rest

or in the up position. When the clutch pedal is fully
depressed on LHD models, the clutch pedal lever
closes the switch, completing the signal circuit from
the PCM and closing the ground path, allowing
engine starter operation. When the clutch pedal is
fully depressed on RHD models, the master cylinder
push rod closes the switch, completing the signal cir-
cuit from the PCM and closing the ground path,
allowing engine starter operation. The interlock
switch is not adjustable.

CLUTCH PEDAL UPSTOP SWITCH

With the clutch pedal at rest, the clutch pedal

upstop switch is closed, allowing speed control oper-
ation. When the clutch pedal is depressed, the upstop
switch opens and signals the PCM to cancel speed
control operation, and enter a modified engine cali-
bration schedule to improve driveability during gear-
to-gear shifts. The upstop switch is not adjustable.

DIAGNOSIS AND TESTING - CLUTCH
INTERLOCK/UPSTOP SWITCH

The LHD clutch interlock/upstop switch is an

assembly consisting of two switches: an engine
starter inhibit switch (interlock) and a clutch pedal
upstop switch (Fig. 9).

The RHD clutch interlock/upstop switch (Fig. 10)

consists of a single, multi-function switch that is acti-
vated by the hydraulic clutch master cylinder push
rod.

Fig. 9 Clutch Interlock/Upstop Switch—LHD

1 - UPSTOP SWITCH
2 - INTERLOCK SWITCH
3 - CONNECTOR

Fig. 10 Clutch Interlock/Upstop Switch—RHD

1 - INTERLOCK/UPSTOP SWITCH
2 - MASTER CYLINDER
3 - CONNECTOR

PL/SRT-4

CLUTCH

6 - 9

CLUTCH INTERLOCK/UPSTOP SWITCH (Continued)

CLUTCH INTERLOCK SWITCH

Mechanical Test

(1) With the park brake set and the transaxle IN

NEUTRAL, turn the ignition key to the start posi-
tion. The engine starter should not crank with the
clutch pedal at rest (not depressed). If the starter
cranks, proceed to the electrical test to determine
whether the switch is defective or the circuit is
shorted. If the vehicle does not crank, proceed to the
next step.

(2) With the park brake set and the transaxle IN

NEUTRAL, fully depress the clutch pedal and turn
the ignition key to the start position. The engine
starter should crank. If the starter does not crank,
visually inspect the clutch pedal for obstructions
(floor mat, etc.). Make sure the clutch pedal lever
contacts and fully closes the switch on LHD applica-
tions, and for proper installation of the master cylin-
der push rod/bushing on the pedal pin on RHD
applications.

Electrical Test

(1) Move ignition key to the “OFF/LOCK” position

and remove key.

(2) Set park brake.
(3) Disconnect the clutch interlock/upstop switch

connector.

(4) Using

an

ohmmeter,

check

for

continuity

between terminals 2 & 3 (Fig. 11) with the interlock
switch not depressed (clutch pedal at rest). There
should be no continuity between the terminals (open
circuit).

(5) LHD Models: Fully depress the clutch pedal to

close the switch. The switch button should compress
at least 1.25 mm (0.050 in.) on LHD applications.
The ohmmeter should show continuity (0 ohms resis-
tance). RHD Models: Disconnect the push rod from
the pedal pin and actuate the push rod by hand to
close the switch. The ohmmeter should show continu-
ity (0 ohms).Inspect the plastic push rod retainer
for damage. If it is damaged (broken/cracked) it
MUST be replaced before reinstalling the push
rod to the pedal.

(6) If ohmmeter readings do not fall within these

ranges, the switch assembly, or the pedal bracket
assembly, is defective and should be replaced. If the
switch tests ok, wiring is defective.

UPSTOP SWITCH

Mechanical Test

(1) Raise vehicle on hoist.
(2) Start engine and operate speed control to main-

tain speed.

(3) Depress clutch pedal at least 33 mm (1.30 in.).

Speed control operation should terminate. If speed
control does not terminate, the upstop switch is
defective or the related wiring is shorted. Proceed to
the upstop switch electrical test.

Electrical Test

(1) Move ignition key to the “OFF/LOCK” position

and remove key.

(2) Set park brake.
(3) Disconnect the clutch interlock/upstop switch

connector.

(4) Using

an

ohmmeter,

check

for

continuity

between terminals 1 & 2 (Fig. 11) with the upstop
switch depressed (clutch pedal at rest). The ohmme-
ter should show continuity (0 ohms).

(5) Depress the clutch pedal at least 33 mm (1.30

in.) check for continuity between terminals 1 & 2.
There should be no continuity between the terminals
(open circuit).

(6) If ohmmeter readings do not fall within these

ranges, the switch assembly is defective and should
be replaced. If the switch tests ok, wiring is defective.

Fig. 11 Interlock/Upstop Switch Connector

1 - INTERLOCK/UPSTOP SWITCH CONNECTOR

6 - 10

CLUTCH

PL/SRT-4

CLUTCH INTERLOCK/UPSTOP SWITCH (Continued)

SERVICE DIAGNOSIS - CLUTCH INTERLOCK/UPSTOP SWITCH

CONDITION

POSSIBLE CAUSES

CORRECTION

ENGINE STARTER WON’T
CRANK WHEN CLUTCH
PEDAL IS PRESSED TO
THE FLOOR

Clutch interlock switch does not have
continuity when plunger is fully
depressed by hand on RHD models,
or switch plunger is depressed 1.25
mm (0.050 in.) on LHD models.

Replace defective pedal bracket assembly
(RHD Models). Replace switch assembly
(LHD Models).

Interlock switch plunger is not
depressed when clutch pedal is
pushed to the floor

Floor mat interferes with clutch pedal
movement, LHD clutch pedal bracket is
bent, or the RHD push rod/bushing is not
properly installed.

Problem is related to other
components in the starting circuit.

Check other components in the starting
circuit. Refer to Battery/Starting/Charging
System in Group 8.

SPEED CONTROL DOES
NOT TERMINATE WHEN
CLUTCH PEDAL IS
DEPRESSED BY AT
LEAST 33 mm (1.30 in.)

Upstop switch circuit is closed when
clutch pedal is depressed, or
harness is shorted.

Refer to Upstop Switch Electrical Test in
this group. Repair wiring or replace switch
assembly as necessary.

Other speed control system failure.

Refer to Group 8H, Speed Control for
further diagnosis and testing procedures.

REMOVAL

LHD

(1) Disconnect and isolate battery negative cable.
(2) Remove left lower instrument panel bezel (Fig.

12).

(3) Disconnect upstop switch and brake lamp

switch connectors.

(4) Disconnect clutch master cylinder rod from

clutch pedal pin. Inspect plastic retainer upon
removal. If retainer is damaged, it MUST be
replaced.

(5) Remove brake booster push rod retaining clip

from brake pedal. Disengage rod from pedal (Fig. 13).

(6) Remove two pedal assembly bracket to instru-

ment panel nuts (Fig. 14).

(7) Remove four brake booster/pedal bracket-to-

cowl panel nuts (Fig. 14).

(8) From under the hood, pull brake master cylin-

der/booster far enough forward to obtain pedal to
bracket stud clearance.

Fig. 12 Steering Column Lower Cover

1 - LOWER COVER

Fig. 13 Brake Booster Mounting Nuts and Rod

Retaining Clip

1 - CLIP
2 - BOOSTER MOUNTING NUTS
3 - BOOSTER MOUNTING NUTS

PL/SRT-4

CLUTCH

6 - 11

CLUTCH INTERLOCK/UPSTOP SWITCH (Continued)