Dodge Neon / Neon SRT-4. Manual — part 363
Fig. 241 Underdrive Clutch Piston, Spring and Retainer
1 - SNAP RING
2 - SPRING RETAINER
3 - SPRING
4 - UD CLUTCH PISTON
5 - SEAL, OUTER
6 - SEAL, INNER
7 - INPUT CLUTCH ASSEMBLY
Fig. 242 Install Underdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 243 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
21 - 236
40TE AUTOMATIC TRANSAXLE
PL/SRT-4
INPUT CLUTCH ASSEMBLY (Continued)
(12) Install the last UD clutch disc (Fig. 244).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 245) (Fig. 246). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
(14) Seat tapered snap ring to ensure proper
installation (Fig. 247) (Fig. 248).
Fig. 244 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 245 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE
UP)
Fig. 246 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 247 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
PL/SRT-4
40TE AUTOMATIC TRANSAXLE
21 - 237
INPUT CLUTCH ASSEMBLY (Continued)
(15) Install input clutch assembly to the Input
Clutch Pressure Fixture–Tool 8391 (Fig. 249).
Fig. 248 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC (3)
4 - SNAP RING (FLAT)
5 - CLUTCH PLATE (3)
6 - INPUT CLUTCH ASSEMBLY
21 - 238
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PL/SRT-4
INPUT CLUTCH ASSEMBLY (Continued)
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 250).
(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
251). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005–0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90° apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB
5.837-5.937 mm (0.230-0.234 in.)
4659940AB
6.147-6.248 mm (0.242-0.246 in.)
4659941AB
6.457-6.557 mm (0.254-0.258 in.)
(21) Install the OD clutch pack (Fig. 252).
Fig. 249 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 250 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 251 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
PL/SRT-4
40TE AUTOMATIC TRANSAXLE
21 - 239
INPUT CLUTCH ASSEMBLY (Continued)
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