DODGE NEON 1999 Service Repair Manual

INSTALLATION
(1) The pivot ball pocket in the fork is Teflon
coated and should be installed WITHOUT any lubri-
cant such as grease. Using grease will break down
the Teflon coating. Be sure the ball stud and fork
pocket are clean of contamination and dirt.
(2) Assemble the fork to the bearing. The small
pegs on the bearing must go over the fork arms.
(3) Slide the bearing and fork assembly onto the
input shaft bearing retainer, as a unit.
(4) Snap the clutch fork onto the pivot ball.
(5) Reinstall transaxle assembly. Refer to Group
21, Transaxle for further information.
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty opera-
tion.
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, or water/
road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main
seal and/or transaxle input shaft. Oil leaks produce a
residue of oil on the transaxle housing interior, clutch
cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-
lubrication. During clutch service, apply only a small
amount of grease to the input shaft splines. Excess
grease may be thrown off during operation, contami-
nating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by
driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing
clutch components to become contaminated. Facing of
disc will absorb moisture and bond to the flywheel
and/or, pressure plate, if vehicle is allowed to stand
for some time before use. If this condition occurs,
replacement of clutch assembly may be required.
Drive the vehicle until normal clutch operating tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
CLEANING PRECAUTIONS
Condensation from steam vapors tend to accumu-
late on the internal clutch mechanism when the vehi-
cle is steam cleaned. Facing of disc will absorb
moisture and will bond to flywheel and/or pressure
plate, if vehicle is allowed to stand for some time
before use. If this condition occurs, it may require
replacement of clutch assembly. After cleaning, drive
the vehicle to its normal clutch operating tempera-
ture. This will dry off disc assembly, pressure plate,
and flywheel.
ADJUSTMENTS
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.
ADJUSTER MECHANISM FUNCTION CHECK
(1) With slight pressure, pull the clutch release
lever end of the cable to draw the cable taut. Push
the clutch cable housing toward the dash panel. With
less than 25 lbs. of effort the cable housing should
move 30-50mm. This indicates proper adjuster mech-
anism function. If the cable does not adjust, deter-
mine if the mechanism is properly seated on the
bracket.
(2) If the adjust mechanism functions properly,
guide the cable through the slot in the transaxle
housing. Connect cable to release lever, seating the
cupped washer securely on lever tangs.
(3) Pull back on clutch cable housing and insert
into transaxle housing (Fig. 7).
Fig. 7 Cable at Transaxle
6 - 10 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(4) Reinstall cable inspection cover and air cleaner
assembly. Check clutch pedal position switch opera-
tion.
CLUTCH PEDAL POSITION 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. 8).
SPECIFICATIONS
TORQUE
MODULAR CLUTCH
DESCRIPTION TORQUE
Drive Plate To Clutch Bolts.....75N´m(55ft.lbs.)
Drive Plate To Crankshaft Bolts . .95 N´m (70 ft. lbs.)
Clutch Pedal Pivot Shaft Nut. . . .41 N´m (30 ft. lbs.)
CONVENTIONAL CLUTCH
DESCRIPTION TORQUE
Clutch Cover Bolts...........28N´m(250 in. lbs.)
Flywheel to Crankshaft Bolts. . . .95 N´m (70 ft. lbs.)
Clutch Pedal Pivot Shaft Nut. . . .41 N´m (30 ft. lbs.)
SPECIAL TOOLS
CLUTCH
Clutch Disc Aligner-6724
Fig. 8 Clutch Pedal Position Switch and
Components
PLCLUTCH 6 - 11
ADJUSTMENTS (Continued)

CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS Ð RIGHT HAND
DRIVE (RHD)........................ 1
CLUTCH DISC AND COVER APPLICATION Ð
RIGHT HAND DRIVE (RHD)............. 1
CLUTCH REPLACEMENT Ð RIGHT HAND
DRIVE (RHD)........................ 1
DESCRIPTION AND OPERATION
CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)................... 2
HYDRAULIC CLUTCH SYSTEM Ð RIGHT
HAND DRIVE (RHD)................... 2
DIAGNOSIS AND TESTING
CLASH±INTO±REVERSE COMPLAINTS...... 6CLUTCH DIAGNOSIS Ð RIGHT HAND DRIVE
(RHD).............................. 2
REMOVAL AND INSTALLATION
CLUTCH ASSEMBLY Ð RIGHT HAND DRIVE
(RHD).............................. 8
CLUTCH MASTER CYLINDER Ð RIGHT HAND
DRIVE (RHD)........................ 6
CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)................... 8
HYDRAULIC SLAVE CYLINDER Ð RIGHT
HAND DRIVE (RHD)................... 7
SPECIFICATIONS
NV T350 (A-578) CLUTCH TIGHTENING
REFERENCE.......................... 9
GENERAL INFORMATION
CLUTCH COMPONENTS Ð RIGHT HAND DRIVE
(RHD)
The modular clutch assembly used in this vehicle
consists of a single, dry-type clutch disc and a dia-
phragm 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 hydraulic clutch system.
The hydraulic clutch automatically adjusts for any
slack in the mechanism. This compensates for clutch
disc wear. The system requires no maintenance or
lubrication.
The clutch pedal is connected to the clutch master
cylinder through a plastic bushing. The upper end of
the clutch pedal pivots in the pedal bracket on twonylon bushings and a shaft (Fig. 1). These bushings
are greased at assembly and do not require periodic
lubrication.
CLUTCH DISC AND COVER APPLICATION Ð
RIGHT HAND DRIVE (RHD)
The1.8L and 2.0L single overhead cam engines use
a 216 mm (8.5 in.) clutch disc.
CLUTCH REPLACEMENT Ð RIGHT HAND DRIVE
(RHD)
The transaxle must be removed to service the mod-
ular clutch assembly, drive plate, and/or clutch
release bearing and lever.
Fig. 1 Clutch Pedal Components
PLCLUTCH 6 - 1

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)