Content .. 53 54 55 56 ..

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.

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

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

—

300

Brake/Clutch Pedal

Assembly-to-Instrument

Panel

—

300

Clutch Cover-to-Flywheel

Bolts

—

250

Clutch Pedal Pivot Shaft

Nut

—

Damper-to-Transaxle Nuts

—

215

Driveplate-to-Crankshaft

Bolts

—

Flywheel-to-Crankshaft

Bolts

—

Master Cylinder Pushrod

Adj. Screw

—

Modular Clutch-to-Drive

Plate Bolts

—

Master Cylinder Mounting

Nuts (LHD)

—

130

Master Cylinder Reservoir

Mounting bolts (LHD)

—

100

Master Cylinder Reservior

Mounting Screw (RHD)

—

Slave Cylinder-to-

Transaxle (2.0L)

—

Slave Cylinder-to-

Transaxle (1.6L)

—

105

Transaxle-to-Engine

Mounting Bolts

—

PL/SRT-4

CLUTCH

6 - 7

CLUTCH (Continued)

Content .. 53 54 55 56 ..