1999 DODGE NEON Service Repair Manual

INSTALL
(1) Connect the wheel speed sensor cable connector
to the vehicle wiring harness (Fig. 36).
(2) Install the speed sensor cable assembly grom-
mets into the retaining bracket (Fig. 38). Installspeed sensor cable routing clip onto the frame of the
vehicle (Fig. 38).
(3) Install wheel speed sensor to steering knuckle
attaching screw (Fig. 37). Torque the attaching screw
to 7 N´m (60 in. lbs.)
(4) Install the wheel and tire assembly on vehicle.
(5) Road test vehicle to ensure proper operation of
the base and ABS systems.
REAR WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel from the vehicle.
(3) Unplug speed sensor cable connector from vehi-
cle wiring harness (Fig. 39). Remove clip (Fig. 39)
attaching speed sensor cable connector to vehicle
body.
(4) Remove the speed sensor cable routing bracket
from under rear brake flex hose mounting bracket.
Then remove the speed sensor cable from the routing
clips on the rear brake flex hose and chassis brake
tube.
(5) Remove bolt (Fig. 40) attaching the rear wheel
speed sensor to the disc brake adapter. Then remove
Fig. 36 Speed Sensor Cable To Wiring Harness
Connection
Fig. 37 Front Wheel Speed Sensor Attaching Bolt
Fig. 38 Front Wheel Speed Sensor Cable Routing
Fig. 39 Rear Speed Sensor Connection To Vehicle
Wiring Harness
5 - 88 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

bolt attaching speed sensor cable routing bracket to
rear strut assembly (Fig. 40).
(6) Remove speed sensor head from the disc brake
adapter. If the speed sensor head has seized in the
adapter, DO NOT USE PLIERS ON SENSOR HEAD.
INSTALL
(1) Install wheel speed sensor head into disc brake
adapter (Fig. 40).
(2) Install wheel speed sensor attaching bolt (Fig.
40). Tighten the attaching bolt to a torque of 7 N´m
(60 in. lbs.)
(3) Install the brake flex hose and wheel speed
sensor cable routing bracket on the rear strut
bracket (Fig. 40).
(4) Install wheel speed sensor cable into the rout-
ing clips on the rear brake flex hose and chassis
brake tube.
(5) Plug speed sensor cable connector into vehicle
wiring harness (Fig. 39). Install clip (Fig. 39) attach-
ing speed sensor cable connector to vehicle body.
(6) Install the tire and wheel assembly on vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS systems.
SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
The total indicator runout allowed for both the
front and rear tone wheel measured using a dial indi-
cator is 0.25 mm (.009 in.).
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE
FRONT WHEEL
Minimum Clearance 0.17 mm (0.007 in.)
Maxamum Clearance 1.80 mm (0.072 in.)
REAR WHEEL
Minimum Clearance 0.37 mm (0.015 in.)
Maxamum Clearance 1.50 mm (0.059 in.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To HCU
At HCU Ports.............21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
MASTER CYLINDER:
To Vacuum Booster
Mounting Nut............28N´m(250 in. lbs.)
BRAKE BOOSTER:
To Dash Panel Mounting Nuts . .28 N´m (250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate
Mounting Bolts............13N´m(115in.lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
REAR DISC BRAKE ADAPTER:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts.............22N´m(192 in. lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
To Mounting Bracket Bolts.....28N´m(250 in. lbs.)
Bracket To Frame Rail
Mounting Bolt (Top)........18N´m(160 in. lbs.)
Bracket To Frame Rail
Mounting Bolts (Side)......22N´m(200 in. lbs.)
PARKING BRAKE:
Lever Mounting Nuts.........28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Knuckle Retaining Nut.....217 N´m (160 ft. lbs.)
WHEEL:
Stud Lug Nut........109±150 N´m (80±110 ft. lbs.)
Fig. 40 Speed Sensor Head Mounting And Cable
Routing
PLBRAKES 5 - 89
REMOVAL AND INSTALLATION (Continued)

CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS................... 1
CLUTCH DISC AND COVER APPLICATION.... 2
CLUTCH REPLACEMENT.................. 2
DESCRIPTION AND OPERATION
CLUTCH CABLE......................... 2
CLUTCH PEDAL POSITION SWITCH......... 2
DIAGNOSIS AND TESTING
CLASH±INTO±REVERSE COMPLAINTS....... 6
CLUTCH CHATTER COMPLAINTS........... 6
CLUTCH COVER AND DISC RUNOUT........ 6
CLUTCH DIAGNOSIS..................... 3
CLUTCH PEDAL POSITION SWITCH......... 2
DRIVE PLATE MISALIGNMENT............. 6
REMOVAL AND INSTALLATION
CLUTCH ASSEMBLY...................... 7CLUTCH CABLE......................... 6
CLUTCH PEDAL POSITION SWITCH......... 7
RELEASE BEARING AND FORK............. 9
CLEANING AND INSPECTION
CLEANING PRECAUTIONS................ 10
CLUTCH CONTAMINATION................ 10
ADJUSTMENTS
CLUTCH CABLE........................ 10
CLUTCH PEDAL POSITION SWITCH........ 11
SPECIFICATIONS
TORQUE.............................. 11
SPECIAL TOOLS
CLUTCH.............................. 11
GENERAL INFORMATION
CLUTCH COMPONENTS
NOTE: Neon vehicles produced at the Toluca
assembly plant, in Mexico, have conventional clutch
and flywheel assemblies. Vehicles produced at Bel-
videre assembly plant have modular clutch assem-
blies.
Before beginning clutch service, check the 11th
character of the V.I.N. to determine where it was
produced. The 11th character is ªDº for vehicles
produced at Belvidere, or ªTº for vehicles produced
at Toluca.
For a vehicle produced at Belvidere assembly,
refer to this manual for service information on the
modular clutch assembly. For a vehicle produced at
Toluca assembly, refer to the following information
to determine proper service procedures.
Service parts stock only a Conventional Clutch
Disc Assembly or a Modular Clutch Service Pack-
age to service Toluca built vehicles. The Modular
Clutch Service Package contains the following
parts:
²One modular clutch assembly
²One drive plate assembly
²One backing plate assembly
²Four drive plate to clutch bolts
²Eight drive plate to crankshaft boltsIf only the clutch disc requires replacement,
obtain the clutch disc. Replace the clutch disc
using the information in the Removal And Installa-
tion section of this manual.
If the clutch pressure plate or flywheel requires
replacement, obtain the Modular Clutch Service
Package. Refer to this manual for service informa-
tion on the modular clutch assembly.
The clutch assembly used in this vehicle consists of
a single, dry-type clutch disc and a diaphragm style
clutch cover.
The clutch disc has cushion springs riveted to the
disc hub assembly. The clutch disc facings are riveted
to the cushion springs. The facings are made from a
non-asbestos material.
The clutch cover pressure plate assembly is a dia-
phragm type unit with a one-piece diaphragm spring
with multiple release fingers. The pressure plate
release fingers are preset during manufacture and
are not adjustable.
A sleeve-type release bearing is used to engage and
disengage the clutch cover pressure plate. The bear-
ing is prelubed during manufacture and is a sealed
unit.
The release bearing is operated by a pivoting
release fork in the clutch housing. The fork pivots on
a ball stud within the housing. The release fork is
actuated by a self-adjusting clutch cable.
PLCLUTCH 6 - 1

The clutch cable has a unique self-adjuster mecha-
nism built into the cable which compensates for
clutch disc wear. The cable requires no maintenance
or lubrication. There are no serviceable components
on the cable assembly.
The clutch pedal is connected to the cable through
a plastic spacer. The upper end of the clutch pedal
pivots in the pedal bracket on two nylon bushings
and a shaft. These bushings are greased at assembly
and do not require periodic lubrication.
CLUTCH DISC AND COVER APPLICATION
The 2.0 single overhead cam engine uses a 216 mm
(8.5 in.) clutch disc. The manual transaxle is avail-
able only with the 2.0 liter engine.
CLUTCH REPLACEMENT
The transaxle must be removed to service the
clutch disc, pressure plate, flywheel/drive plate,
and/or clutch release bearing and lever.
DESCRIPTION AND OPERATION
CLUTCH CABLE
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear. This adjuster mechanism is located
within the clutch cable assembly. The preload spring
maintains tension on the cable. This tension keeps
the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 1).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
the switch is in its normal (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050), the ohmmeter should show continuity (zero
ohms).
If ohmmeter readings do not fall within these
ranges, the switch is defective, and must be replaced.
SERVICE DIAGNOSIS±CLUTCH PEDAL POSITION SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WON'T CRANK
WHEN CLUTCH PEDAL IS
PRESSED TO THE FLOORSwitch does not have continuity
when plunger is depressed 1.25
mmDefective switch. Replace switch.
Switch plunger is not depressed
when clutch pedal is pushed to the
floorFloor mat interferes with clutch pedal
movement. Move floor mat out of the way.
Problem is related to other
components in the starting circuitCheck other components in the starting
circuit. Refer to Section 8A, Battery/Starting/
Charging System.
Fig. 1 Clutch Pedal Position Switch and
Components
6 - 2 CLUTCHPL
GENERAL INFORMATION (Continued)

CLUTCH PEDAL POSITION
SWITCH±MECHANICAL TEST
With the park brake set and the vehicleIN NEU-
TRAL,turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is
defective (shorted out) and must be replaced. If the
vehicle does not crank, proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.
With the park brake set and the vehicleIN GEAR,
turn the key to the start position and hold it there.
Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there
is no motion, the switch is working properly.
If motion is felt, check to see if the switch is mak-
ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch orthe self-adjusting cable (See ªClutch Will Not Disen-
gage Properlyº). If this condition is not met, then the
switch mounting tab on the brake bracket is bent,
and the brake bracket must be replaced.
If vehicle will not crank, even with clutch pedal
pressed to the floor, refer to ªService Diagnosis-
Clutch Pedal Position Switchº chart in this section.
CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road
test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSISÐCLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft sealCorrect leak and replace w/modular clutch
assembly
Too much grease applied to splines
of disc and input shaftApply lighter coating of grease to splines
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline componentFurther diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly)Replace w/modular clutch assembly
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for damage.
Correct as necessary.
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSISÐCLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT Normal wear. Replace w/modular clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear overheating.Replace w/modular clutch assembly
Insufficient clutch cover diaphragm
spring tensionReplace w/modular clutch assembly
CLUTCH DISC FACING
CONTAMINATED WITH OIL
OR GREASELeak at rear main oil seal or
transaxle input shaft sealReplace leaking seals. Replace w/modular
clutch assembly.
Excessive amount of grease
applied to input shaft splinesApply less grease to input shaft. Replace
w/modular clutch assembly
Road splash, water entering
housingSeal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY DISENGAGEDRelease 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.
Cable self-adjuster mechanism
sticking or binding causing high
preloadVerify that self-adjuster is free to move
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECESDriver performs a 5-1 downshift at
vehicle speed in excess of 60 miles
per hourAlert driver to problem cause. Replace
w/modular clutch assembly.
Leak at rear main or transaxle input
shaft sealReplace w/modular clutch assembly.
Replace seal.
Excessive heat from slippage Replace w/modular clutch assembly
6 - 4 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSISÐIMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINESClutch disc hub splines damaged
during installationClean, smooth, and lubricate disc and shaft
splines. Replace w/modular 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 discClean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED TO
FLYWHEEL AND/OR
PRESSURE PLATEOccurs 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 w/modular clutch assembly
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace w/modular clutch assembly
Clutch cover diaphragm spring
damaged during transaxle
installationReplace w/modular clutch assembly
Release fork bent, loose, or
damagedReplace fork if worn or damaged
Clutch cable binding or routed
incorrectlyCheck and correct cable routing
Self-adjuster in cable not
functioning properly, resulting in
excess cable slackPull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL MAKES
REPEATED9POP9NOISE
IN THE FIRST INCH OF
TRAVELSelf-adjusting mechanism in cable
defectiveReplace clutch cable
CLUTCH PEDAL SQUEAKS
WHEN DEPRESSED TO
FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings
Clutch pedal return spring worn out Replace return spring
PLCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)