Dodge Neon / Neon SRT-4. Manual - part 59

INSTALLATION

INSTALLATION - T350 MODELS

NOTE: These models are equipped with a one-piece
master/slave cylinder assembly. If the master cylin-
der requires replacement, the master AND slave cyl-
inder must be replaced with a two-piece “quick-
connect” system. If the slave cylinder requires
replacement, the slave cylinder is serviced sepa-
rately.

(1) Install the master cylinder into position on the

dash panel. Route the hydraulic tube underhood as
noted upon removal.

(2) Install the self-docking connector bracket.
(3) Install the master cylinder retaining nuts onto

the master cylinder studs. Tighten the nuts to 11
N·m (100 in.lbs.).

(4) Install the master cylinder remote reservoir

onto the dash panel.

(5) Install the reservoir retaining screws. Tighten

the screws to 11 N·m (103 in.lbs.).

(6) Install the brake booster.

CAUTION: Inspect the clutch master cylinder push
rod plastic retainer for damage. If it is damaged
(broken/cracked), it MUST be replaced.

(7) Raise vehicle on hoist.
(8) If master cylinder is being replaced, install ser-

vice replacement slave cylinder. If master cylinder is

being re-used, install slave cylinder as shown in (Fig.
29).

(9) If master cylinder is being replaced, connect

the master cylinder hydraulic line to the service
replacement slave cylinder hydraulic line. An audible
click should be heard. Verify the connection by pull-
ing outward on the master cylinder line.

(10) Lower vehicle.
(11) Loosen the push rod adjustment screw (Fig.

37).

(12) Install the push rod onto the pedal pin.
(13) Gently lift clutch pedal upwards until the

clutch pedal fully depresses the upstop switch.
Torque adjustment screw to 6 N·m (55 in. lbs.).

(14) Install the ABS module/purge solenoid, PDC,

and air cleaner.

(15) 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)

(16) Connect the negative battery cable.
(17) Top off clutch master cylinder reservoir with

DOT 3 brake fluid.

(18) Verify correct clutch operation.

INSTALLATION - T850 MODELS

(1) Install the master cylinder into position on the

dash panel.

(2) Install the self-docking connector bracket.
(3) Install the master cylinder retaining nuts onto

the master cylinder studs. Tighten the nuts to 11
N·m (100 in.lbs.).

(4) Route

the

hydraulic

tube

noted

upon

removal.

Fig. 36 Clutch Master Cylinder (LHD)

1 - MASTER CYLINDER
2 - RESERVOIR
3 - RETAINER CLIP
4 - RETAINER CLIP

Fig. 37 Clutch Master Cylinder Pushrod Adjustment

Screw

1 - ADJUSTMENT SCREW

6 - 20

CLUTCH

PL/SRT-4

MASTER CYLINDER-LHD (Continued)

(5) Connect the master cylinder hydraulic line to

the slave cylinder hydraulic line. An audible click
should be heard. Verify the connection by pulling out-
ward on the master cylinder line.

(6) Install the master cylinder remote reservoir

onto the dash panel.

(7) Install the reservoir retaining screws. Tighten

the screws to 11 N·m (103 in.lbs.).

(8) Install the brake booster.

CAUTION: Inspect the clutch master cylinder push
rod plastic retainer for damage. If it is damaged
(broken/cracked), it MUST be replaced.

(9) Loosen the push rod adjustment screw (Fig.

38).

(10) Install the push rod onto the pedal pin.
(11) Gently lift clutch pedal upwards until the

clutch pedal fully depresses the upstop switch.
Torque adjustment screw to 6 N·m (55 in. lbs.).

(12) Install the ABS module/purge solenoid, PDC,

and air cleaner.

(13) Depress and release the clutch pedal a mini-

(14) Connect the negative battery cable.
(15) Top off clutch master cylinder reservoir with

DOT 3 brake fluid.

(16) Verify correct clutch operation.

MASTER CYLINDER-RHD

DESCRIPTION

NOTE: A one-piece master/slave cylinder assembly
is used on these models. If the master cylinder
requires replacement, the master AND slave cylin-
ders must be replaced with a two-piece system.

The RHD clutch master cylinder (Fig. 39) mounts

through the dash panel and to the pedal bracket
assembly. The master cylinder consists of a push rod,
a piston and cylinder housing, a remote fluid reser-
voir, an interconnecting hydraulic tube, and an inte-
gral slave cylinder (Fig. 40).

REMOVAL

NOTE: Replacement master cylinder assemblies
come pre-filled with fluid. No fluid service or sys-
tem

bleeding

should

required,

unless

the

hydraulic system has lost an excessive amount of
fluid and has ingested air into the slave cylinder
assembly.

Fig. 38 Clutch

1 - ADJUSTMENT SCREW

Fig. 39 Clutch Master Cylinder—RHD

1 - MASTER CYLINDER
2 - RESERVOIR
3 - DASH PANEL

PL/SRT-4

CLUTCH

6 - 21

MASTER CYLINDER-LHD (Continued)

(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Remove slave cylinder from transaxle (Fig. 41)
(4) Remove hydraulic hose (Fig. 42) from the clips

along the frame rail and the dash panel.

(5) Lower vehicle.
(6) Remove the two screws holding the master cyl-

inder remote reservoir to the dash panel.

(7) Disconnect the master cylinder push rod from

the pedal pin. Inspect plastic retainer. If retainer
is damaged in any way, it MUST be replaced.

(8) Remove

the

clutch

interlock/upstop

switch

cover plate and switch housing (Fig. 43) from the
master cylinder push rod.

(9) From the engine compartment, grasp the mas-

ter cylinder body and rotate approximately 45° in a
counter-clockwise direction.

(10) Disengage the master cylinder from the pedal

bracket assembly.

(11) Remove the master cylinder from the vehicle.

If difficulty is encountered in removing the master/
slave cylinder assembly, cut the hydraulic tube to
divide the system into two pieces and remove.

INSTALLATION

Fig. 40 Clutch Hydraulic System - RHD

1 - RESERVOIR
2 - MASTER CYLINDER
3 - PEDAL ASSEMBLY
4 - SLAVE CYLINDER

Fig. 41 Clutch Slave Cylinder at Transaxle- 2.0L

Models

1 - SLAVE CYLINDER
2 - BRACKET

Fig. 42 Clutch Master Cylinder-XXX-RHD

1 - MASTER CYLINDER
2 - RESERVOIR
3 - RETAINER
4 - RETAINER

6 - 22

CLUTCH

PL/SRT-4

MASTER CYLINDER-RHD (Continued)

NOTE: Replacement master cylinder assemblies
come pre-filled with fluid. No fluid service or sys-
tem bleeding should be required.

(1) Install the master cylinder into position on the

dash panel. (Fig. 44).

(2) Seat the master cylinder in the pedal bracket

assembly.

(3) Rotate the master cylinder approximately 45°

in the clockwise direction.

(4) Route

the

hydraulic

tube

noted

upon

removal.

(5) Raise vehicle on hoist.
(6) If master cylinder is being replaced, install ser-

vice replacement slave cylinder. If master cylinder is
being re-used, install slave cylinder as shown in (Fig.
41).

(7) If master cylinder is being replaced, connect

the master cylinder hydraulic line to the service
replacement slave cylinder hydraulic line. An audible
click should be heard. Verify the connection by pull-
ing outward on the master cylinder line.

(8) Lower vehicle.
(9) Install the master cylinder remote reservoir

onto the dash panel.

(10) Install the reservoir retaining screws. Tighten

the screws to 3 N·m (24 in.lbs.).

(11) Install the clutch interlock/upstop switch and

cover plate. (Fig. 45)

CAUTION: Inspect the clutch master cylinder push
rod plastic retainer for damage. If it is damaged
(broken/cracked), it MUST be replaced.

Fig. 43 Clutch Interlock/Upstop Switch

1 - INTERLOCK/UPSTOP SWITCH
2 - MASTER CYLINDER
3 - CONNECTOR

Fig. 44 Clutch Master Cylinder—RHD

1 - MASTER CYLINDER
2 - RESERVOIR
3 - RETAINER
4 - RETAINER

Fig. 45 Clutch Interlock/Upstop Switch

1 - INTERLOCK/UPSTOP SWITCH
2 - MASTER CYLINDER
3 - CONNECTOR

PL/SRT-4

CLUTCH

6 - 23

MASTER CYLINDER-RHD (Continued)

Content .. 57 58 59 60 ..