Dodge Neon / Neon SRT-4. Manual — part 60
(12) Install the push rod onto the pedal pin.
(13) Depress and release the clutch pedal a mini-
mum of ten (10) times to allow any residual air in
the system to be vented to the reservoir. If residual
air becomes trapped in the system, bleed the clutch
hydraulic system. (Refer to 6 - CLUTCH - STAN-
DARD PROCEDURE)
(14) Connect the negative battery cable.
(15) Top off clutch master cylinder reservoir with
DOT 3 brake fluid.
(16) Verify proper clutch operation.
MODULAR CLUTCH
DESCRIPTION
The modular clutch assembly (Fig. 46) is located
between the engine and manual transaxle in the
transaxle bellhousing, and is responsible for trans-
mitting engine power to the transaxle. The modular
clutch assembly consists of the following components:
• Flywheel
• Clutch Disc
• Pressure Plate
• Diaphragm Spring
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Remove modular clutch assembly (Fig. 47) from
transaxle input shaft.
INSPECTION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty opera-
tion.
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, or water/
road splash on clutch components.
OIL
Oil contamination indicates a leak at the rear main
seal and/or transaxle input shaft. Oil leaks produce a
residue of oil on the transaxle housing interior, clutch
cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
black.
GREASE
Grease contamination is usually a product of over-
lubrication. During clutch service, apply only a small
amount of grease to the input shaft splines. Excess
grease may be thrown off during operation, contami-
nating the disc.
ROAD SPLASH/WATER
Road splash contamination is usually caused by
driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing
clutch components to become contaminated. Facing of
disc will absorb moisture and bond to the flywheel
and/or, pressure plate, if vehicle is allowed to stand
for some time before use. If this condition occurs,
replacement of clutch assembly may be required.
Drive the vehicle until normal clutch operating tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
Extreme use of steam cleaning equipment on the
engine compartment or vehicle undercarriage can
have the same effect.
Fig. 46 Modular Clutch Assembly
1 - MODULAR CLUTCH ASSEMBLY
6 - 24
CLUTCH
PL/SRT-4
MASTER CYLINDER-RHD (Continued)
INSTALLATION
(1) Install clutch module (Fig. 47) onto input shaft.
(2) Install transaxle into vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
SLAVE CYLINDER
DESCRIPTION
The clutch slave cylinder integral to the clutch
master cylinder and is fastened to transaxle bell-
housing (Fig. 48), and consists of a hydraulic piston
and cylinder, seal and return spring.
REMOVAL
REMOVAL - T350 MODELS
(1) Raise vehicle on hoist.
(2) Remove cotter key from hydraulic tube-to-slave
cylinder connection point.
(3) Using a suitable punch, drive out roll pin and
discard.
(4) Remove slave cylinder mounting bolts (Fig. 49).
(5) Remove slave cylinder from transaxle and sep-
arate from hydraulic tube. Allow brake fluid to drain
into suitable container.
REMOVAL - T850 MODELS
(1) Raise vehicle on hoist.
(2) Using Tool 6638A, disconnect hyrdraulic clutch
circuit quick connect fitting.
Fig. 47 Transaxle Removal/Installation
1 - MODULAR CLUTCH ASSEMBLY
2 - CLIP
3 - TRANSAXLE
4 - CLUTCH MODULE BOLT (4)
Fig. 48 Clutch Slave Cylinder at Transaxle- 2.0L
Models
1 - SLAVE CYLINDER
2 - BRACKET
PL/SRT-4
CLUTCH
6 - 25
MODULAR CLUTCH (Continued)
(3) Remove clutch slave cylinder (Fig. 50) by lifting
nylon tab with a small screwdriver, and then
depressing cylinder inward towards case and rotating
cylinder 60° counter-clockwise.
INSTALLATION
INSTALLATION - T350 MODELS
(1) Install the slave cylinder assembly into position
on transaxle (Fig. 49).
(2) Tighten slave cylinder-to-transaxle bolts to 19
N·m (168 in. lbs.).
(3) Connect clutch hydraulic supply tube to slave
cylinder. Install NEW roll pin and cotter key.
(4) Lower vehicle.
(5) Verify clutch master cylinder reservoir is full.
Top off with DOT 3 brake fluid if necessary.
(6) Bleed clutch hydraulic system (Refer to 6 -
CLUTCH - STANDARD PROCEDURE).
(7) Verify proper clutch release system operation.
INSTALLATION - T850 MODELS
(1) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs. While depress-
ing inward, rotate slave cylinder clockwise until
nylon locating tab rests in transaxle case cutout, and
the hydraulic tube is vertical (Fig. 50).
(2) Connect “quick-connect” connection until an
audible “click” is heard. Verify connection by pulling
outward on connection.
(3) Lower vehicle.
Fig. 49 Clutch Slave Cylinder at Transaxle—2.0L
Models
1 - SLAVE CYLINDER
2 - BRACKET
Fig. 50 Slave Cylinder Removal/Installat
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
6 - 26
CLUTCH
PL/SRT-4
SLAVE CYLINDER (Continued)
COOLING
TABLE OF CONTENTS
page
page
COOLING
. . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . 35
COOLING
WARNING
COOLING SYSTEM WARNINGS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASED COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPENED OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DISPOSE OF GLYCOL BASED COOLANT PROP-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CENTER
IN YOUR AREA. DO NOT OPEN A COOLING SYS-
TEM WHEN THE ENGINE IS AT OPERATING TEM-
PERATURE
OR
HOT
UNDER
PRESSURE,
PERSONAL INJURY CAN RESULT. AVOID RADIA-
TOR COOLING FAN WHEN ENGINE COMPARTMENT
RELATED SERVICE IS PERFORMED, PERSONAL
INJURY CAN RESULT.
SPECIFICATIONS
TORQUE - 2.0L SOHC
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Screws, A/C Condenser to
Radiator
7.2
-
65
Bolt, Automatic Belt Tensioner
Pulley
27
20
-
Nut/Screw, Coolant Recovery
Container
4
-
35
Coolant Temperature Sensor
18
-
165
Screws, Radiator Fan to
Radiator
7.2
-
65
Screws, Radiator Fan Motor to
Shroud
3.8
-
34
Nut, Radiator Fan Blade to
Motor Shaft
6.2
-
55
Screw, In-Rush Current
Supressor
2.6
-
23
Pivot Bolt, Generator Mounting
54
40
-
Locking Nut, Generator
Mounting
54
40
-
Screws, Radiator (Cooling
Module) to Body
10
-
90
Screws, Thermostat
Housing/Water Outlet
Connector
12
-
105
Bolts, Water Pump to Engine
Block
12
-
105
Bolts, Water Pump Inlet Tube
to Engine Block
12
-
105
PL/SRT-4
COOLING
7 - 1
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