light DODGE NEON 1999 Service Owner's Manual

and performance characteristics of the ABS. See the
ABS System Operation Section in this group of the
service manual to familiarize yourself with the oper-
ating principles of the ITT Teves Mark 20 ABS sys-
tem.
ABS SERVICE PRECAUTIONS
The ABS uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure.These circuits should only be tested
using a high impedance multi-meter or the DRB
tester as described in this section. Power should
never be removed or applied to any control module
with the ignition in the ON position. Before removing
or connecting battery cables, fuses, or connectors,
always turn the ignition to the OFF position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equippedwith antilock brakes may affect the function of the
antilock brake system.
ABS WIRING DIAGRAM INFORMATION
During the diagnosis of the antilock brake system
it may become necessary to reference the wiring dia-
grams covering the antilock brake system and its
components. For wiring diagrams refer to Antilock
Brakes in Group 8W of this service manual. This
group will provide you with the wiring diagrams and
the circuit description and operation information cov-
ering the antilock brake system.
ABS DIAGNOSTICS MANUAL
Detailed procedures for diagnosing specific ABS
conditions are covered in the diagnostics manual cov-
ering the ITT Teves Mark 20 ABS system. The fol-
lowing information is presented to give the
technician a general background on the diagnostic
capabilities of the ITT Teves Mark 20 ABS system.
Please refer to the above mentioned manual for any
further electronic diagnostics and service procedures
that are required.
Fig. 11 Normal Braking Hydraulic Circuit
5 - 76 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

DRB DIAGNOSTIC SCAN TOOL USAGE
The diagnostics of the ITT Teves Mark 20 ABS sys-
tem used on this vehicle is performed using the DRB
scan tool. Refer to the diagnostics manual covering
the ITT Teves Mark 20 ABS system for the required
diagnostics ans testing procedures and the DRB oper-
ators manual for its proper operational information.
DRB DIAGNOSTIC CONNECTOR
On this vehicle, the diagnostics connector used for
diagnosing the Teves Mark 20 ABS system is located
under the steering column lower cover, to the left
side of the steering column (Fig. 14). The Teves Mark
20 ABS system uses the CCD connector which is
shared by other vehicle diagnostic systems such as
the powertrain control module and air bag.
ABS SYSTEM SELF DIAGNOSTICS
The ITT Teves Mark 20 ABS system is equipped
with a self diagnostic capability which may be used
to assist in the isolation of ABS faults. The features
of the self diagnostics system are described below.
START-UP CYCLE
The self diagnostic ABS start up cycle begins when
the ignition switch is turned to the on position. Elec-
trical checks are completed on ABS components, suchas the Controller, solenoid continuity, and the system
relay operation. During this check the Amber ABS
Warning Light is turned on for approximately 5 sec-
onds and the brake pedal may emit a popping sound
and move slightly when the solenoid valves are
checked.
DRIVE-OFF CYCLE
Further Functional testing is accomplished once
the vehicle is set in motion and reaches a speed of
about 20 kph (12 mph.). This cycle is performed only
once after each ignition on/off cycle.
²The pump/motor is activated briefly to verify
function. When the pump/motor is activated a whirl-
ing or buzzing sound may be heard by the driver,
which is normal when the pump/motor is running.
²The wheel speed sensor output is verified to be
within the correct operating range.
ONGOING TESTS
Other tests are performed on a continuous basis.
These include checks for solenoid continuity, wheel
speed sensor continuity and wheel speed sensor out-
put.
Fig. 12 ABS Mode Hydraulic Circuit
PLBRAKES 5 - 77
DIAGNOSIS AND TESTING (Continued)

ABS DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC) are kept in the con-
troller's memory until either erased by the technician
using the DRB or erased automatically after 3500
miles or 255 key cycles which ever occurs first. DTC's
are retained by the controller even if the ignition isturned off or the battery is disconnected. More than
one DTC can be stored at a time. The key cycle num-
ber of occurrences and the DTC that was stored is
also displayed. Most functions of the CAB and the
ABS system can be accessed by the technician for
testing and diagnostic purposes by using the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTC's detected by the CAB are latching; the
DTC is latched and ABS braking is disabled until the
ignition switch is reset. Thus ABS braking is non
operational even if the original DTC has disappeared.
Other DTC's are non-latching; any warning lights
that are turned on, are only turned on as long as the
DTC condition exists. As soon as the condition goes
away, the ABS Warning Light is turned off, although
a DTC will be set in most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As with virtually any electronic system, intermit-
tent electrical problems in the ABS system may be
difficult to accurately diagnose.
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. When an
intermittent fault is encountered, check suspect cir-
cuits for:
Fig. 13 ABS Mode Secondary Hydraulic Circuit
Fig. 14 ABS System Diagnostic Connector Location
5 - 78 BRAKESPL
DIAGNOSIS AND TESTING (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)

DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose 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.
CLUTCH COVER AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(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. If
chatter persists:
(2) Check to see if clutch cable routing is correct
and operates smoothly.
(3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary.
CLASH±INTO±REVERSE COMPLAINTS
Certain NV T350 (A-578) manual transaxles are
equipped with a reverse brake. It prevents 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.
(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 CABLE
REMOVAL
(1) Pull up and remove Power Distribution Center.
(2) Remove clutch cable inspection cover.
(3) Pull back on clutch cable housing and disen-
gage cable from housing (Fig. 2).
Fig. 2 Cable at Transaxle
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

(4) Guide cable through slot in transaxle and dis-
connect cable from release lever.
(5) Disconnect clutch cable up-stop/spacer with
cable strand from clutch pedal.
NOTE: Depressing the clutch pedal provides
access to the clutch cable strand. Disconnect the
cable up-stop/spacer from the pedal pivot pin by
removing the snap ring at the top of the clutch
pedal. Wedge a flat±blade pry tool between the pin
and the retaining tab. While holding the tab slightly
separated from the pin, pull the up-stop/spacer off
the pedal. Now remove the cable end from the up-
stop/spacer.
CAUTION: Do not pull on the clutch cable to
remove it from the dash panel. Damage to the cable
self-adjuster may occur.
(6) Remove the cable from the cable routing tube
and clutch bracket.
INSTALLATION
(1) Insert the self±adjuster mechanism end of the
clutch cable through the cable routing tube and into
the bracket.
(2) Be sure the self±adjuster is firmly seated
against the clutch bracket to ensure proper adjuster
mechanism function.
(3) Connect the clutch cable to the up-stop/spacer.
(4) Connect the up-stop/spacer to the clutch pedal.
(5) Install snap ring to hold up-stop spacer in
place.
(6) Perform the Adjuster Mechanism Function
Check before finishing installation.
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
mechanism function. If the cable does not adjust,
determine if the mechanism is properly seated on the
bracket tube.
(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. 2).
(4) Reinstall cable inspection cover and PDC.
Check clutch pedal position switch operation.
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. 3).
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 the
switch 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
Neon vehicles produced at the Toluca assembly
plant, in Mexico, have conventional clutch and fly-
wheel assemblies. Vehicles produced at Belvidere
assembly plant have modular clutch assemblies.
TOLUCA BUILT VEHICLES
The transaxle must be removed to service the
clutch disc, flywheel, clutch cover and/or the release
bearing and lever.
Fig. 3 Clutch Pedal Position Switch and
Components
PLCLUTCH 6 - 7
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(2) Mark clutch cover and flywheel, to maintain
their same relative positions when installing clutch
assembly.
(3) Insert Clutch Disc Aligning Tool 6724 through
the clutch disc hub to prevent the clutch disc from
falling and damaging the facings (Fig. 4).
(4) Loosen clutch cover attaching bolts, one or two
turns at a time, in a crisscross pattern. This will
release spring pressure evenly and avoid cover dam-
age.
CAUTION: Do not touch the clutch disc facing with
oily or dirty hands. Oil or dirt transferred from your
hands onto the clutch disc facing may cause clutch
chatter.
(5) Remove the clutch pressure plate and cover
assembly and disc from flywheel. 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.
(2) The friction faces of the flywheel and pressure
plate should not have excessive discoloration, burned
areas, cracks, deep grooves, or ridges. Replace parts
as required.
(3) Clean the flywheel face with medium sandpa-
per (80-180 grade), then wipe the surface with min-
eral spirits. If the surface is severely scored, heat
checked, cracked or warped, replace the flywheel.CAUTION: Do not flat-machine the flywheel face.
The surface profile is tapered.
(4) The heavy side of the flywheel is indicated by a
daub of white paint near the outside diameter. To
minimizethe effects of flywheel unbalance, perform
the following installation procedure:
²Loose assemble the flywheel to the crankshaft.
Use new flywheel attaching bolts which have sealant
on the threads. If new bolts are not available, apply
Loctite sealant to the threads of the original bolts.
This sealant is required to prevent engine oil leak-
age.
²Rotate the flywheel and crankshaft until the
daub of white paint (heavy side) is at the 12 o'clock
position.
²Torque flywheel attaching bolts to 95 N´m (70 ft.
lbs.). Use a crisscross pattern when tightening bolts.
(5) The disc assembly should be handled without
touching the facings. Replace disc if the facings show
evidence of grease or oil soakage, or wear to within
less than .20 mm (.008 inch) of the rivet heads. The
splines on the disc hub and transaxle input shaft
should be a snug fit without signs of excessive wear.
Metallic portions of disc assembly should be dry,
clean, and not discolored from excessive heat. Each of
the arched springs between the facings should not be
broken and all rivets should be tight.
(6) Wipe the friction surface of the pressure plate
with mineral spirits.
(7) Using a straight edge, check pressure plate for
flatness. The pressure plate friction area should be
FLAT TO SLIGHTLY CONCAVE, with the inner
diameter 0.000 mm to 0.1 mm (0.000 in. to 0.0039
in.) below the outer diameter. It should also be free
from discoloration, burned areas, cracks, grooves, or
ridges.
(8) Using a surface plate, test cover for flatness.
All sections around attaching bolt holes should be in
contact with surface plate within .015 inch.
(9) The cover should be a snug fit on flywheel dow-
els. If the clutch assembly does not meet these
requirements, it should be replaced.
INSTALLATION
(1) Mount clutch assembly on flywheel with disc
centered with tool 6724, being careful to properly
align dowels and the alignment marks made before
removal. The flywheel side of the clutch disc is
marked for proper installation. If new clutch or fly-
wheel is installed, align orange cover balance spot as
close as possible to orange flywheel balance spot.
Apply pressure to the alignment tool. Center the tip
of the tool into the crankshaft and the sliding cone
into the clutch fingers. Tighten the clutch attaching
bolts sufficiently to hold the disc in position (Fig. 5).
Fig. 4 Clutch Disc Aligning Tool
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(2) To avoid distortion of the clutch cover, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 28 N´m (250 in. lbs.) following a crisscross
pattern sequence. Remove clutch disc alignment tool.
(3) Install transaxle. See Group 21, Manual Tran-
saxle for procedures.
BELVIDERE BUILT VEHICLES
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. 6). 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.
(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.
RELEASE BEARING AND FORK
Remove the transaxle from the vehicle. See Group
21, Transaxle for removal and installation proce-
dures.
REMOVAL
(1) Move the lever and bearing assembly to a ver-
tical in-line position. Grasp the release lever with
two hands in the pivot stud socket area. Pull with
even pressure and the lever will pop off the pivot-
±stud. Do not use a screwdriver or pry bar to pop off
the lever. This may damage the spring clip on the
lever.
(2) As a unit, remove the fork from the bearing
thrust plate. Be careful not to damage retention tabs
on bearing.
(3) Examine the condition of the bearing.It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(4) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(5) Check the condition of the pivot stud spring
clips on back side of clutch fork. If the clips are bro-
ken or distorted, replace the clutch fork.
Fig. 6 Clutch ComponentsFig. 5 Clutch Installation
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

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)

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)