1999 DODGE NEON Service Repair Manual

DESCRIPTION AND OPERATION
HYDRAULIC CLUTCH SYSTEM Ð RIGHT HAND
DRIVE (RHD)
The hydraulic clutch linkage consists of a clutch
master cylinder, remote hydraulic fluid reservoir,
lower clutch slave cylinder, damper, and hydraulic
lines. The clutch master cylinder is connected to the
clutch pedal. The slave cylinder push rod is con-
nected to the clutch release fork. The clutch master
cylinder is mounted on the driver's side of the dash
panel adjacent to the brake master cylinder and
booster assembly.
NOTE: The clutch hydraulic system is serviced as
two separate systems (master cylinder assembly
w/lines and lower slave cylinder assembly w/lines. If
a malfunction occurs within a system, replacement
of that system is required. It is not recommended or
necessary to bleed the clutch hydraulic system. The
service parts are prefilled.
CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)
For description, operation, and diagnosis of the
clutch pedal position switch refer to the Left Hand
Drive (LHD) information for the clutch pedal position
switch.
DIAGNOSIS AND TESTING
CLUTCH DIAGNOSIS Ð RIGHT HAND DRIVE
(RHD)
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.
Fig. 2 Clutch Pedal Position Switch and
Components Ð Right Hand Drive (RHD)
6 - 2 CLUTCHPL

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 and
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 housing Seal 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.
Hydraulic clutch mechanism sticking
or binding causing high preloadVerify that clutch slave cylinder and
fork are 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 pedal binding or does not
returnLubricate pedal bushings. Check
system for leaks and replace as
needed
Hydraulic clutch system has air in
the lines.Stroke pedal rapidly 20 to 30 times
to force air bubbles into reservoir.
Check for leaks. Replace appropriate
upper or lower hydraulic system.
PLCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL SQUEAKS
WHEN DEPRESSED TO FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings
CLASH±INTO±REVERSE COMPLAINTS
Some Right Hand Drive NV T350 (A-578) manual
transaxles are equipped with a reverse brake. It pre-
vents clash when shifting into reverse, but only if the
vehicle is not moving. See Group 21, Transaxle for
further diagnosis.
(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.
NOTE: Verify that nothing is obstructing pedal
travel. Floormats or other articles located under-
neath the clutch pedal could prevent the clutch
from disengaging fully. Also make sure that the
hydraulic clutch release mechanism is functioning
properly.
(2) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(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.
REMOVAL AND INSTALLATION
CLUTCH MASTER CYLINDER Ð RIGHT HAND
DRIVE (RHD)
The clutch master cylinder and remote reservoir
are serviced as an assembly. The linkage components
and cylinder cannot be overhauled or serviced sepa-
rately.
REMOVAL
(1) Hoist vehicle.
(2) Disconnect quick-connector coupler at lower
hydraulic damper using Special Tool 6638 (Fig. 3).(3) Lower vehicle.
(4) Unsnap hydraulic line from left rail retainer
clips (Fig. 4).
(5) From underneath dash panel, remove cotter
pin from pedal bushing.
(6) Remove pedal pivot pin from master pushrod
assembly and bushing.
NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
removal.
(7) Slide remote reservoir up out of bracket.
Fig. 3 Quick-Connect Coupler
Fig. 4 Routing Clips
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

(8) Grasp clutch master cylinder and turn 1/4 turn
counterclockwise (Fig. 5).
(9) Remove cylinder from dash panel.
INSTALLATION
NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
installation.
(1) Position clutch master cylinder to dash panel
approximately 45É counterclockwise. (Fig. 6).
(2) Position master cylinder push rod so that
retention fingers are facing towards the right side of
the vehicle.
(3) Insert push rod through dash panel hole and
slide push rod eye between the clutch pedal and loca-
tor bracket.
(4) Rotate cylinder 1/4 turn clockwise.
(5) Slide remote reservoir into bracket at dash
panel until locked in.(6) From underneath dash panel, ensure clutch
master cylinder push rod is located between the
pedal and locator bracket. Snap clutch pedal pin into
pushrod and slide cotter pin into bushing.
(7) Route hydraulic lines to retaining clips at
frame rail.
(8) Raise vehicle.
(9) Connect upper clutch hydraulic line from mas-
ter cylinder (quick±connect) to lower clutch hydraulic
line near damper.
(10) Check the operation of the hydraulic clutch
release system.
(11) Actuate clutch pedal rapidly 20±30 times.
Check for leaks
HYDRAULIC SLAVE CYLINDER Ð RIGHT HAND
DRIVE (RHD)
REMOVAL
(1) Raise vehicle on hoist.
(2) Separate hydraulic line at quick-disconnect
using Special Tool 6638. (Fig. 7).
(3) Remove nuts retaining hydraulic damper to
transaxle (Fig. 8).
(4) Remove engine mount bracket.
(5) Disconnect ground wire from starter.
(6) Remove two bolts retaining hydraulic slave cyl-
inder to transaxle (Fig. 8).
(7) Remove slave cylinder from transmission.
INSTALLATION
CAUTION: When reinstalling starter wiring, make
certain wiring does not contact hydraulic tubing.
(1) To install, reverse above procedure.
(2) Actuate clutch pedal 20±30 times. Check for
leaks.
Fig. 5 Hydraulic Clutch Master Cylinder
Fig. 6 Master Cylinder at Dash PanelFig. 7 Hydraulic Line
PLCLUTCH 6 - 7
REMOVAL AND INSTALLATION (Continued)

CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)
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. 9).
REMOVAL
(1) Disconnect electrical harness to switch connec-
tor.
(2) Depress wing tabs on switch and push switch
out of mounting bracket. Then slide wires through
slot in bracket.
INSTALLATION
(1) Slide switch wires through slot in switch
bracket.
(2) Line up switch tab with slot in switch bracket
and push switch into position. Do not pull on theswitch wires to seat switch into bracket, switch dam-
age may occur.
(3) Attach switch wiring harness to vehicle wiring
harness.
(4) After installation, the switch must be checked
for proper operation. Refer to Diagnosis and Testing
section for proper testing procedures.
CLUTCH ASSEMBLY Ð RIGHT HAND DRIVE (RHD)
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
(3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
(5) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(6) The transaxle and modular clutch come out as
an assembly.
(7) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 10). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.
NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
Fig. 8 Damper and Slave Cylinder
Fig. 9 Clutch Pedal Position Switch and
ComponentsFig. 10 Clutch Components
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(3) To avoid distortion of the drive plate, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 75 N´m (55 ft. lbs.) following a crisscross pat-
tern sequence.
(4) Install clutch inspection cover.
(5) Install transaxle lower support brackets.
(6) Install starter assembly.SPECIFICATIONS
NV T350 (A-578) CLUTCH TIGHTENING
REFERENCE
DESCRIPTION TORQUE
Drive Plate To Clutch Bolts....75N´m(55ft.lbs.)
Drive Plate To Crankshaft Bolts . 95 N´m (70 ft. lbs.)
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)