Dodge Neon / Neon SRT-4. Manual — part 57
(9) Remove the pedal bracket assembly (Fig. 14).
(10) Remove pedal pivot shaft and remove brake
and clutch pedals.
(11) Remove the interlock/upstop switch assembly
(Fig. 15) from the brake/clutch pedal bracket assembly
by depressing the four plastic wing tabs on each switch.
RHD
(1) Disconnect the master cylinder push rod from
the pedal pin (Fig. 16). Inspect push rod retainer
for damage. If it is damaged (broken/cracked),
it must be replaced.
(2) Squeeze together the tangs on the switch cover
plate and slide the plate off the switch housing.
(3) Disconnect the clutch interlock/upstop switch
connector from the instrument panel wiring harness.
(4) Remove the switch from the vehicle.
INSTALLATION
LHD
NOTE: Proper switch harness routing is critical to
switch durability. Note the harness routing and
location of fasteners intended to keep wires from
contacting pedals.
(1) Install switches into the pedal bracket assem-
bly as shown in (Fig. 15). Route harness as was prior
to removal. Secure switch connector retaining push
pin into the appropriate hole in the pedal bracket
assembly.
Fig. 14 Brake/Clutch Pedal Assembly Removal/
Installation
1 - CLUTCH/BRAKE PEDAL ASSEMBLY
2 - INTERLOCK/UPSTOP SWITCH CONNECTOR
Fig. 15 Interlock/Upstop Switch
1 - UPSTOP SWITCH
2 - INTERLOCK SWITCH
3 - CLUTCH PEDAL
4 - CONNECTOR
Fig. 16 Clutch Interlock/Upstop Switch
1 - INTERLOCK/UPSTOP SWITCH
2 - MASTER CYLINDER
3 - CONNECTOR
6 - 12
CLUTCH
PL/SRT-4
CLUTCH INTERLOCK/UPSTOP SWITCH (Continued)
(2) Install
clutch
and
brake
pedals
to
pedal
bracket, and install pivot shaft and nut. Torque pivot
shaft nut to 42 N·m (31 ft. lbs.).
(3) Install brake/clutch pedal bracket assembly
into position. Install and tighten brake booster
mounting nuts to 34 N·m (25 ft. lbs.). Install and
tighten pedal bracket-to-instrument panel nuts to 34
N·m (25 ft. lbs.).
(4) Install new stop lamp switch.
(5) Connect brake booster rod to brake pedal.
Install retainer clip (Fig. 13).
(6) Loosen adjustment screw (Fig. 17).
CAUTION: Inspect clutch master cylinder pushrod
plastic retainer. If retainer is damaged in any way
(broken/cracked) it MUST be replaced.
(7) Connect clutch master cylinder pushrod. Gently
lift clutch pedal upwards until the clutch pedal fully
depresses the the upstop switch. Torque adjustment
screw to 6 N·m (55 in. lbs.).
(8) Connect interlock/upstop and stop lamp switch
connectors.
(9) Install left lower instrument panel bezel (Fig.
12).
(10) Connect battery negative cable.
(11) Verify proper switch operation.
RHD
NOTE: Proper switch harness routing is critical to
switch durability. Note the harness routing and
location of fasteners intended to keep wires from
contacting pedals.
(1) Install the clutch interlock/upstop switch onto
the master cylinder push rod, making sure that the
push rod is oriented with the push rod retainer
toward the wiring of the switch. The master cylinder
push rod must be snapped into the clutch interlock/
upstop switch along the smaller diameter of the push
rod between the snap ring and the transition to the
larger diameter.
CAUTION: Improper assembly of the larger diameter
of the push rod into the clutch interlock/upstop
switch could cause damage to the switch or a
clutch system failure.
(2) Install the switch cover plate.
CAUTION: Inspect the plastic push rod retainer for
damage. If it is damaged (broken/cracked), it MUST
be replaced.
(3) Connect clutch master cylinder pushrod to the
clutch pedal pin.
(4) Route the wiring harness as it was prior to
removal.
(5) Secure the switch connector retaining push pin
into the appropriate hole in the pedal bracket assem-
bly.
CLUTCH RELEASE BEARING
AND LEVER
DESCRIPTION
T350-Equipped Models
A conventional release bearing is used to engage
and disengage the clutch pressure plate. The clutch
release bearing is mounted on the transaxle front
bearing retainer. The bearing is attached to and oper-
ated by the release lever (Fig. 18), which moves the
bearing into contact with the clutch cover diaphragm
spring.
T850-Equipped Models
A conventional release bearing is used to engage
and disengage the clutch pressure plate. The clutch
release bearing is mounted on the transaxle front
bearing retainer. The bearing is attached to and oper-
ated by the release lever (Fig. 19), which moves the
bearing into contact with the clutch cover diaphragm
spring.
Fig. 17 Clutch Master Cylinder Pushrod Adjustment
Screw
1 - ADJUSTMENT SCREW
PL/SRT-4
CLUTCH
6 - 13
CLUTCH INTERLOCK/UPSTOP SWITCH (Continued)
OPERATION
The release bearing is operated by the release
lever. Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward, relieving clamping force on the clutch
disc.
Releasing
pedal
pressure
removes
clutch
hydraulic pressure. The release bearing then moves
away from the diaphragm spring which allows the
pressure plate to exert clamping force on the clutch
disc.
REMOVAL
REMOVAL - T350 MODELS
(1) Remove the transaxle from the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove modular clutch assembly (if equipped).
(3) Move the lever and bearing assembly to a ver-
tical in-line position (Fig. 18). Grasp the release lever
with two hands in the pivot stud socket area. Pull
with even pressure and the lever will pop off the piv-
ot–stud. Do not use a screwdriver or pry bar to pop
off the lever. This may damage the spring clip on the
lever.
(4) As a unit, remove the lever from the bearing
thrust plate. Be careful not to damage retention tabs
on bearing.
(5) Examine the condition of the bearing. It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(6) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(7) Check the condition of the pivot stud spring
clips on back side of clutch lever. If the clips are bro-
ken or distorted, replace the clutch lever.
REMOVAL - T850 MODELS
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/T850
MANUAL
-
REMOVAL)
(2) Remove modular clutch assembly from input
shaft.
Fig. 18 Clutch Release Bearing and Lever (T350)
1 - RELEASE BEARING
2 - LEVER
Fig. 19 Clutch Release Bearing and Lever (T850)
1 - RELEASE LEVER
2 - RELEASE BEARING
6 - 14
CLUTCH
PL/SRT-4
CLUTCH RELEASE BEARING AND LEVER (Continued)
(3) Grasp clutch release lever and bearing (Fig. 20)
with both hands and pull outward using moderate
pressure to release lever from pivot ball(s).
(4) Separate release bearing from lever.
NOTE: Remove release lever pivot ball(s) ONLY if
replacement is necessary.
(5) Remove
pivot
ball(s)
using
slide
hammer
C-3752 and remover/installer 6891 (Fig. 21).
INSTALLATION
INSTALLATION - T350 MODELS
(1) The pivot ball pocket in the lever, as well as
the lever arms should be lubricated with grease prior
to installation.
(2) Assemble the lever to the bearing. The small
pegs on the bearing must go over the lever arms.
(3) Slide the bearing and lever assembly onto the
input shaft bearing retainer, as a unit (Fig. 18).
(4) Snap the clutch lever onto the pivot ball.
(5) Install modular clutch assembly (if equipped).
(6) Reinstall transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
INSTALLATION - T850 MODELS
(1) If removed, install new release lever pivot
ball(s) using slide hammer C-3752 and remover/in-
staller 6891 (Fig. 22) (Fig. 23).
Fig. 20 Release Bearing and Lever—2.4L Turbo
Models
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 21 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 22 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
PL/SRT-4
CLUTCH
6 - 15
CLUTCH RELEASE BEARING AND LEVER (Continued)
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