Dodge Neon / Neon SRT-4. Manual — part 55
CONDITION
POSSIBLE CAUSES
CORRECTION
Road splash, water entering housing
Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY DISENGAGED
Release bearing sticking or binding,
does not return to normal running
position.
Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.
Clutch master cylinder pushrod not
adjusted properly, causing high
preload (LHD Models).
Verify that pushrod adjustment is correct.
Slave cylinder binding
Replace slave cylinder.
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
Leak at rear main or transaxle input
shaft seal
Replace seal. Replace clutch assembly.
Excessive heat from slippage
Replace clutch assembly
SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINES
Clutch disc hub splines damaged
during installation
Clean, smooth, and lubricate disc and shaft
splines. Replace clutch assembly and/or
input shaft if splines are severely damaged.
Input shaft splines rough, damaged.
Clean input shaft splines. Then lube.
Corrosion or rust formations on
splines of input shaft and disc
Clean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE
Occurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.
Replace clutch assembly
CLUTCH WILL NOT
DISENGAGE PROPERLY
Disc bent, distorted during transaxle
installation
Replace clutch assembly
Clutch cover diaphragm spring
damaged during transaxle
installation
Replace clutch assembly
Release lever bent, loose, or
damaged
Replace release lever if worn or damaged
Clutch master cylinder or slave
cylinder leaking
Check and replace master and/or slave
cylinder
Master cylinder adjustable pushrod
loose or damaged (LHD models)
Inspect. Tighten adjustment fastener or
replace master cylinder
Master cylinder push rod not
retained to pedal pin.
Inspect pushrod and bushing. Replace as
necessary
6 - 4
CLUTCH
PL/SRT-4
CLUTCH (Continued)
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR
Pedal bushings worn out or
inadequate lubrication
Replace or lubricate bushings
Clutch pedal return spring or return
spring bushing worn out
Lubricate or replace return spring and/or
bushing
Clutch release lever pivot stud has
inadequate lubrication
Lubricate or replace clutch release lever
DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly.
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky
or binding. Replace bearing, if needed.
(c) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(d) Check clutch assembly for contamination
(dirt, oil). Replace clutch assembly, if required.
(e) Check to see if the clutch disc hub splines
are damaged. Replace with new clutch assembly, if
necessary.
(f) Check
input
shaft
splines
for
damage.
Replace, if necessary.
(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly,
if necessary.
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
• Heat warping
• Mounting drive plate on a dirty crankshaft
flange
• Incorrect bolt tightening
• Improper seating on the crankshaft shoulder
• Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
DIAGNOSIS AND TESTING - CLASH-INTO-
REVERSE COMPLAINTS
All T350 manual transaxles are equipped with a
reverse brake. It prevents clash when shifting into
reverse, but only if the vehicle is not moving.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.
(2) Remove transaxle.
(3) Check the input shaft spline, clutch disc
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check
for
broken
clutch
cover
diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.
STANDARD PROCEDURE—BLEEDING CLUTCH
HYDRAULIC CIRCUIT
NOTE: It is necessary to bleed the clutch hydraulic
release system if the system has lost an excessive
amount of fluid and has ingressed air into the cir-
cuit. Air in the system typically results in a spongy
pedal feel, and/or improper clutch release. If air
cannot be removed from the system using this pro-
cedure, it is necessary to replace BOTH the clutch
master cylinder and slave cylinder assemblies.
PL/SRT-4
CLUTCH
6 - 5
CLUTCH (Continued)
2.0/2.4L Engines (Except Turbo)
From driver’s seat, actuate clutch pedal 60–100
times. Verify clutch operation/pedal feel. If pedal still
feels spongy, or clutch does not fully disengage,
excessive air is still trapped within the system. Per-
form the following procedure:
(1) Verify fluid level in clutch master cylinder res-
ervoir. Top off with DOT 3 brake fluid as necessary.
(2) Raise vehicle on hoist.
(3) Remove clutch slave cylinder assembly from
the transaxle case (Fig. 4), but do not disconnect
from the system. Allow the slave cylinder hang,
making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the
transaxle, DO NOT actuate the clutch master cylin-
der. Damage to the slave cylinder will result.
(4) Depress slave cylinder pushrod until it bottoms
and then release. Repeat this at least ten (10) times,
forcing trapped air upwards and out of the system.
(5) Re-install slave cylinder into position. Torque
slave cylinder to case bolt to 19 N·m (168 in. lbs.).
(6) Lower vehicle.
(7) Check and adjust clutch master cylinder fluid
level. Actuate clutch pedal thirty (30) times. Verify
clutch operation/pedal feel. If pedal still feels spongy,
or clutch does not fully disengage, air is still trapped
within the system. Repeat Step 3 - Step 7 until air is
purged. If several attempts at purging air from the
system are unsuccessful, replace both the clutch mas-
ter cylinder and slave cylinder assemblies.
(8) Raise vehicle.
(9) Lower vehicle.
(10) Top off clutch master cylinder fluid level with
DOT 3 brake fluid as necessary.
2.4L Engine (With Turbo)
From driver’s seat, actuate clutch pedal 60–100
times. Verify clutch operation/pedal feel. If pedal still
feels spongy, or clutch does not fully disengage,
excessive air is still trapped within the system. Per-
form the following procedure:
(1) Verify fluid level in clutch master cylinder res-
ervoir. Top off with DOT 3 brake fluid as necessary.
(2) Raise vehicle on hoist.
(3) Remove clutch slave cylinder/damper assembly
from the transaxle case (Fig. 5), but do not discon-
nect from the hydraulic system. Lift nylon tab
with a small screwdriver, and then depress cylinder
inward towards case and rotating cylinder 60°
counter-clockwise. Allow the slave cylinder hang,
making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the
transaxle, DO NOT actuate the clutch master cylin-
der. Damage to the slave cylinder will result.
(4) Depress slave cylinder pushrod until it bottoms
and then release. Repeat this at least ten (10) times,
forcing trapped air upwards and out of the system.
(5) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs. While depress-
ing inward, rotate slave cylinder clockwise until
Fig. 4 Clutch Slave Cylinder - 2.0/2.4L
1 - SLAVE CYLINDER
2 - BRACKET
Fig. 5 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
6 - 6
CLUTCH
PL/SRT-4
CLUTCH (Continued)
nylon locating tab rests in transaxle case cutout, and
the hydraulic tube is vertical (Fig. 5).
(6) Lower vehicle.
(7) Check and adjust clutch master cylinder fluid
level. Actuate clutch pedal thirty (30) times. Verify
clutch operation/pedal feel. If pedal still feels spongy,
or clutch does not fully disengage, air is still trapped
within the system. Repeat Step 3 - Step 7 until air is
purged. If several attempts at purging air from the
system are unsuccessful, replace both the clutch mas-
ter cylinder and slave cylinder assemblies.
(8) Raise vehicle.
(9) Lower vehicle.
(10) Top off clutch master cylinder fluid level with
DOT 3 brake fluid as necessary.
SPECIFICATIONS
CLUTCH/HYDRAULICS/PEDALS
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Brake/Clutch Pedal &
Booster-to-Dash Nuts
34
—
300
Brake/Clutch Pedal
Assembly-to-Instrument
Panel
34
—
300
Clutch Cover-to-Flywheel
Bolts
29
—
250
Clutch Pedal Pivot Shaft
Nut
42
31
—
Damper-to-Transaxle Nuts
24
—
215
Driveplate-to-Crankshaft
Bolts
95
70
—
Flywheel-to-Crankshaft
Bolts
95
70
—
Master Cylinder Pushrod
Adj. Screw
6
—
55
Modular Clutch-to-Drive
Plate Bolts
88
65
—
Master Cylinder Mounting
Nuts (LHD)
15
—
130
Master Cylinder Reservoir
Mounting bolts (LHD)
11
—
100
Master Cylinder Reservior
Mounting Screw (RHD)
3
—
24
Slave Cylinder-to-
Transaxle (2.0L)
19
14
—
Slave Cylinder-to-
Transaxle (1.6L)
12
—
105
Transaxle-to-Engine
Mounting Bolts
95
70
—
PL/SRT-4
CLUTCH
6 - 7
CLUTCH (Continued)
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