Dodge Neon / Neon SRT-4. Manual — part 58

(2) Install clutch release bearing to lever. Apply

grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 24).

(3) Apply grease to pivot ball, and on release lever

at slave cylinder contact point.

(4) Install clutch release bearing/lever assembly

into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball (Fig. 25). A “pop” sound
should be heard. Verify proper engagement by lightly

pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.

(5) Reinstall transaxle assembly (Refer to 21 -

TRANSMISSION/TRANSAXLE/T 850 MANUAL -
INSTALLATION)

MASTER CYLINDER-LHD

DESCRIPTION

NOTE: A one-piece master/slave cylinder assembly
is used on T350 models. If the master cylinder
requires replacement, the master AND slave cylin-
ders must be replaced with a two-piece system.

The LHD clutch master cylinder mounts to the

dash panel (Fig. 26). The master cylinder consists of
an adjustable push rod, a piston and cylinder hous-
ing, a remote fluid reservoir, an interconnecting
hydraulic tube, and an integral slave cylinder (Fig.
27).

Fig. 23 Pivot Ball Orientation (RHD)

1 - PIVOT BALL (1)

Fig. 24 Release Bearing-to-Lever

1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING

Fig. 25 Release Bearing and Lever—2.4L Turbo

Models

1 - RELEASE LEVER
2 - RELEASE BEARING

6 - 16

CLUTCH

PL/SRT-4

CLUTCH RELEASE BEARING AND LEVER (Continued)

REMOVAL

REMOVAL - T350 Models

NOTE: These models are equipped with a one-piece
master/slave cylinder assembly. If the master cylin-
der requires replacement, the master AND slave cyl-
inder must be replaced with a two-piece “quick-
connect” system. If the slave cylinder requires
replacement, the slave cylinder is serviced sepa-
rately.

NOTE: Replacement master cylinder assemblies
come pre-filled with fluid. No fluid service or sys-
tem

bleeding

should

be

required,

unless

the

hydraulic system has lost an excessive amount of
fluid and has ingested air into the slave cylinder
assembly.

(1) Remove air cleaner assembly (Fig. 28).

(2) Disconnect battery negative cable.
(3) Raise vehicle on hoist.
(4) Remove slave cylinder from transaxle (Fig. 29).
(5) Remove hydraulic hose from left rail retainers

(Fig. 32).

(6) Lower vehicle.
(7) Remove PDC bracket and position out of way.
(8) Remove lower instrument panel bezel (Fig. 30).
(9) Remove clip and disconnect the brake booster

input rod from the brake pedal pin (Fig. 31).

Fig. 26 Clutch Master Cylinder—LHD

1 - MASTER CYLINDER
2 - RESERVOIR
3 - RETAINER CLIP
4 - RETAINER CLIP

Fig. 27 Clutch Master Cylinder—LHD

1 - RESERVOIR
2 - MASTER CYLINDER
3 - ADJUSTMENT BOLT
4 - QUICK CONNECT (T850 ONLY)

Fig. 28 Air Cleaner Assembly Removal/Installation

1 - AIR CLEANER ASSY.
2 - THROTTLE BODY DUCT

PL/SRT-4

CLUTCH

6 - 17

MASTER CYLINDER-LHD (Continued)

(10) Remove the brake booster mounting nuts (Fig.

31).

(11) Slide brake booster forward enough to gain

access to and remove clutch master cylinder.

(12) Remove clutch master cylinder reservoir (Fig.

32).

(13) Disconnect clutch master cylinder rod from

clutch pedal. Inspect plastic retainer. If retainer
is broken or damaged in any way, it MUST be
replaced upon reassembly.

(14) Remove two clutch master cylinder retaining

nuts.

(15) Remove the self-docking connector bracket.

CAUTION: Use care when removing clutch master
cylinder from engine compartment. Aggressive han-
dling can result in a damaged hydraulic tube and
improper clutch release operation upon reassembly.

(16) Remove master cylinder from mounting posi-

tion and carefully work hydraulic pipe from out of
engine compartment (Fig. 32). If necessary, unfasten
ABS module and purge solenoid assembly to gain
necessary clearance. If difficulty is encountered in
removing system from vehicle, cut master cylinder
hydraulic tube to divide system into two pieces.

Fig. 29 Clutch Slave Cylinder at Transaxle- 2.0L

Models

1 - SLAVE CYLINDER
2 - BRACKET

Fig. 30 Steering Column Lower Cover

1 - LOWER COVER

Fig. 31 Brake Booster Mounting Nuts

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

Fig. 32 Clutch Master Cylinder—LHD

1 - MASTER CYLINDER
2 - RESERVOIR
3 - RETAINER CLIP
4 - RETAINER CLIP

6 - 18

CLUTCH

PL/SRT-4

MASTER CYLINDER-LHD (Continued)

REMOVAL - T850 MODELS

NOTE: Replacement master cylinder assemblies
come pre-filled with fluid. No fluid service or sys-
tem

bleeding

should

be

required,

unless

the

hydraulic system has lost an excessive amount of
fluid and has ingested air into the slave cylinder
assembly.

(1) Remove air cleaner assembly.
(2) Disconnect battery negative cable.
(3) Raise vehicle on hoist.
(4) Using Tool 6638A, disconnect clutch hydraulic

quick-connect (Fig. 33).

(5) Remove hydraulic hose from left rail retainers

(Fig. 36).

(6) Lower vehicle.
(7) Remove PDC bracket and position out of way.
(8) Remove lower instrument panel bezel (Fig. 34).
(9) Remove clip and disconnect the brake booster

input rod from the brake pedal pin (Fig. 35).

(10) Remove the brake booster mounting nuts (Fig.

35).

(11) Slide brake booster forward enough to gain

access to and remove clutch master cylinder.

(12) Remove clutch master cylinder reservoir (Fig.

36).

(13) Disconnect clutch master cylinder rod from

clutch pedal. Inspect plastic retainer. If retainer
is broken or damaged in any way, it MUST be
replaced upon reassembly.

(14) Remove two clutch master cylinder retaining

nuts.

(15) Remove the self-docking connector bracket.

CAUTION: Use care when removing clutch master
cylinder from engine compartment. Aggressive han-
dling can result in a damaged hydraulic tube and
improper clutch release operation upon reassembly.

(16) Remove master cylinder from mounting posi-

tion and carefully work hydraulic pipe from out of
engine compartment (Fig. 36). If necessary, unfasten
ABS module and purge solenoid assembly to gain
necessary clearance.

Fig. 33 Disconnect Hydraulic Circuit Usi

1 - QUICK CONNECT FITTING
2 - TOOL 6638A

Fig. 34 Steering Column Lower Cover

1 - LOWER COVER

Fig. 35 Brake Booster Mounting Nuts

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

PL/SRT-4

CLUTCH

6 - 19

MASTER CYLINDER-LHD (Continued)