DODGE NEON 2000 Service Repair Manual

CAUTION: When removing a wheel speed sensor
from the knuckle, do not use pliers on the sensor
head. This may damage the sensor head. If the sen-
sor has seized, use a hammer and a punch to tap
the edge of the sensor head ear, rocking the sensor
side-to-side until free.
(5) Carefully, remove the sensor head from the
steering knuckle.(6) Remove the screw securing the wheel speed
sensor to the rear of the strut (Fig. 20). Remove the
wheel speed sensor.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Attach the wheel speed sensor to the strut
using the its mounting screw (Fig. 20).
(2) Install the wheel speed sensor head in the
steering knuckle (Fig. 19). Install the mounting bolt.
Tighten the mounting bolt to a torque of 12 N´m (105
in. lbs.).
(3) From the sensor bracket on the strut, loop the
sensor cable upward, then downward at the outside
of the frame rail. Install the speed sensor cable grom-
met onto the retaining bracket attached to the brake
hose on the outside of the frame rail.
(4) Loop the wheel speed sensor cable around the
bottom of the frame rail and connect it to the wiring
harness connector on the inside of the frame rail
(Fig. 18). Remember to push in the locking tab on the
connector.
(5) Install the tire and wheel assembly.
(6) Lower the vehicle.
(7) Road test vehicle to ensure proper operation of
the base brakes and ABS.
Fig. 18 Wiring Harness Connector
1 ± RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 ± RIGHT FRONT DRIVESHAFT
3 ± ENGINE OIL FILTER
Fig. 19 Wheel Speed Sensor
1 ± RIGHT FRONT WHEEL SPEED SENSOR
2 ± TONE WHEEL
Fig. 20 Wheel Speed Sensor At Strut
1 ± ABS WHEEL SPEED SENSOR ROUTING BRACKET (IF
EQUIPPED)
2 ± GROUND STRAP
3 ± GROUND STRAP SCREW
4 ± ABS SENSOR BRACKET SCREW (IF EQUIPPED)
5 - 82 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

WHEEL SPEED SENSOR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Disconnect the wheel speed sensor cable con-
nector from the vehicle wiring harness (Fig. 21).
Remove the clip attaching wheel speed sensor cable
connector to the vehicle's body.
(4) Remove the wheel speed sensor cable routing
bracket from under rear brake flex hose mounting
bracket. Then remove the speed sensor cable from
the routing clips on the rear brake flex hose and
chassis brake tube.
(5) Remove the bolt attaching the wheel speed sen-
sor cable routing bracket to rear strut.
CAUTION: When removing a wheel speed sensor
from the rear disc brake adapter, do not use pliers
on the sensor head. This may damage the sensor
head. If the sensor has seized, use a hammer and apunch to tap the edge of the sensor head ear, rock-
ing the sensor side-to-side until free.
(6) Remove the bolt attaching the wheel speed sen-
sor to the rear disc brake adapter (Fig. 22), then
carefully remove the sensor head from the rear disc
brake adapter and vehicle.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Install the wheel speed sensor head into the
disc brake adapter (Fig. 22).
(2) Install the wheel speed sensor mounting bolt.
Tighten the mounting bolt to a torque of 12 N´m (105
in. lbs.).
(3) Install the wheel speed sensor cable routing
bracket on the rear strut.
(4) Install wheel speed sensor cable into the rout-
ing clips on the rear brake hose and brake tube.
(5) Connect the wheel speed sensor cable connector
into vehicle wiring harness (Fig. 21). Install the clip
attaching the wheel speed sensor cable connector to
vehicle's body.
(6) Install the tire and wheel assembly on vehicle.
(7) Lower the vehicle.
(8) Road test the vehicle to ensure proper opera-
tion of the base brakes and ABS.
Fig. 21 Wheel Speed Sensor Connector
1 ± FUEL TANK
2 ± TENSION STRUT
3 ± WHEEL SPEED SENSOR CONNECTOR
4 ± LOCKING TAB
5 ± CLIP
Fig. 22 Rear Wheel Speed Sensor
1 ± RIGHT REAR WHEEL SPEED SENSOR
2 ± TENSION STRUT
PLBRAKES 5 - 83
REMOVAL AND INSTALLATION (Continued)

DISASSEMBLY AND ASSEMBLY
INTEGRATED CONTROL UNIT
REMOVAL
NOTE: To replace the hydraulic control unit (HCU)
or the controller antilock brake (CAB) on this vehi-
cle, the entire integrated control unit (ICU) needs to
be removed from the vehicle. The CAB can then be
separated from the HCU. Do not attempt to replace
the CAB with the ICU mounted in the vehicle.
(1) Remove the ICU from the vehicle. Refer INTE-
GRATED CONTROL UNIT in the REMOVAL AND
INSTALLATION section in this section of the service
manual.
(2) Disconnect the pump/motor wiring harness
(Fig. 23) from the CAB.
(3) Remove the 4 bolts (Fig. 24) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 25).
INSTALLATION
(1) Install the CAB (Fig. 25) on the HCU.(2) Install the 4 bolts mounting the CAB (Fig. 24)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 23).
(4) Install the ICU in the vehicle.
(5) Bleed the base and ABS hydraulic systems.
Refer to ANTILOCK BRAKE SYSTEM BLEEDING
in this section of this service manual group.
(6) Road test the vehicle to ensure proper opera-
tion of the base brakes and ABS.
Fig. 23 Pump/Motor To CAB Wiring Harness
1 ± CAB
2 ± PUMP MOTOR WIRING HARNESS
3 ± PUMP MOTOR
4 ± HCU VALVE BLOCK
Fig. 24 CAB Attaching Bolts
1 ± MOUNTING BOLTS
2 ± CAB
3 ± HCU VALVE BLOCK
Fig. 25 Remove/Install CAB
1 ± CAB
2 ± HCU VALVES
3 ± HCU VALVE BLOCK
5 - 84 BRAKESPL

SPECIFICATIONS
TONE WHEEL RUNOUT
FRONT TONE WHEEL:
Maximum Runout.........0.25 mm (0.009 in.)
REAR TONE WHEEL:
Maximum Runout.........0.25 mm (0.009 in.)
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE
FRONT WHEEL:
Minimum Clearance.......0.28 mm (0.011 in.)
Maximum Clearance.......1.42 mm (0.056 in.)
REAR WHEEL:
Minimum Clearance.......0.45 mm (0.018 in.)
Maximum Clearance.......1.12 mm (0.044 in.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts............... 17N´m(145 in. lbs.)
MASTER CYLINDER:
Mounting Nuts.......... 28N´m(250 in. lbs.)
POWER BRAKE BOOSTER:
Mounting Nuts.......... 34N´m(300 in. lbs.)
DISC BRAKE CALIPER:
Caliper Banjo Bolt......... 48N´m(35ft.lbs.)
Guide Pin Bolts.......... 22N´m(192 in. lbs.)
Bleeder Screw........... 15N´m(125 in. lbs.)
WHEEL CYLINDER (REAR):
Mounting Bolts.......... 13N´m(115in.lbs.)
Bleeder Screw............ 10N´m(80in.lbs.)
DRUM BRAKE SHOE SUPPORT PLATE
(REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
DISC BRAKE ADAPTER (REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
HUB AND BEARING (REAR):
Retaining Nut.......... 217N´m(160 ft. lbs.)
PARKING BRAKE:
Lever Mounting Nuts..... 28N´m(250 in. lbs.)
TIRE AND WHEEL:
Wheel Mounting Nut...........109±150 N´m
(80±110 ft. lbs.)
INTEGRATED CONTROL UNIT:
Mounting Bolts........... 11N´m(97in.lbs.)
CAB Mounting bolts........ 2N´m(17in.lbs.)
Bracket-to-Frame Rail Bolts.......... 23N´m
(200 in. lbs.)
WHEEL SPEED SENSOR:
Head Mounting bolt...... 12N´m(105 in. lbs.)
PLBRAKES 5 - 85

CLUTCH
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
MODULAR CLUTCH ASSEMBLY..............1
CLUTCH CABLE..........................1
CLUTCH INTERLOCK/UPSTOP SWITCH........1
DIAGNOSIS AND TESTING
CLUTCH SYSTEM DIAGNOSIS...............2
DRIVE PLATE MISALIGNMENT..............5
CLUTCH CHATTER COMPLAINTS............5
CLASH±INTO±REVERSE COMPLAINTS........5
CLUTCH INTERLOCK/UPSTOP SWITCH........5REMOVAL AND INSTALLATION
CLUTCH CABLE..........................7
CLUTCH INTERLOCK/UPSTOP SWITCH........8
MODULAR CLUTCH ASSEMBLY..............8
RELEASE BEARING AND FORK.............12
CLEANING AND INSPECTION
CLUTCH CONTAMINATION.................12
CLEANING PRECAUTIONS.................13
SPECIFICATIONS
TORQUE...............................13
DESCRIPTION AND OPERATION
MODULAR CLUTCH ASSEMBLY
All 2.0L SOHC engines equipped with the A578
5-speed transaxle use a modular clutch assembly
(Fig. 1). The transaxle must be removed to gain
access to and replace the modular clutch, drive plate,
and/or clutch release bearing and lever.
The modular clutch assembly used in this vehicle
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover is riveted to the flywheel, containing theclutch disc within. The modular clutch can only be
serviced as an assembly.
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.
CLUTCH CABLE
The clutch cable assembly (Fig. 2) carries the
movement of the clutch pedal to the clutch release
bearing. The cable is designed to maintain tension
against the clutch fork, or lever, and has a built in
self-adjusting mechanism, which compensates for
clutch disc wear.
CLUTCH INTERLOCK/UPSTOP SWITCH
DESCRIPTION
The clutch interlock/upstop switch is an assembly
consisting of two switches: an engine starter inhibit
switch (interlock) and a clutch pedal upstop switch
(Fig. 3). The switch assembly is located in the clutch/
brake pedal bracket assembly (Fig. 4), each switch
being fastened by four plastic wing tabs.
OPERATION
Clutch Interlock Switch
The clutch interlock switch prevents engine starter
operation and inadvertent vehicle movement with the
clutch engaged and the transaxle in gear.
Fig. 1 Modular Clutch Assembly
1 ± MODULAR CLUTCH ASSEMBLY
PLCLUTCH 6 - 1

The switch is open while the clutch pedal is at
rest. When the clutch pedal is fully depressed, the
pedal blade contacts and closes the switch, sending a
signal to the PCM, allowing engine starter operation.
The interlock switch is not adjustable.
Clutch Pedal Upstop Switch
With the clutch pedal at rest, the clutch pedal
upstop switch is closed, allowing speed control oper-
ation. When the clutch pedal is depressed, the upstop
switch opens and signals the PCM to cancel speed
control operation, and enter a modified engine cali-
bration schedule to improve driveability during gear-
to-gear shifts. The upstop switch is not adjustable.
DIAGNOSIS AND TESTING
CLUTCH SYSTEM DIAGNOSIS
Clutch 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 Cable Assembly
1 ± ADJUSTER MECHANISM
2 ± CLUTCH CABLE
Fig. 3 Clutch Interlock/Upstop Switch
1 ± UPSTOP SWITCH
2 ± INTERLOCK SWITCH
3 ± CONNECTOR
Fig. 4 Clutch/Brake Pedal Bracket Assembly
1 ± UPSTOP SWITCH
2 ± CLUTCH PEDAL
3 ± INTERLOCK SWITCH
4 ± CONNECTOR
6 - 2 CLUTCHPL
DESCRIPTION AND OPERATION (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 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 modular clutch assembly
Clutch disc damaged or distorted Replace 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.
SERVICE DIAGNOSISÐCLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING
WORN OUTNormal wear. Replace modular clutch assembly.
Driver frequently rides (slips) clutch, results
in rapid wear overheating.Replace modular clutch assembly
Insufficient clutch cover diaphragm spring
tensionReplace modular clutch assembly
CLUTCH DISC
FACING
CONTAMINATED
WITH OIL OR
GREASELeak at rear main oil seal or transaxle input
shaft sealReplace leaking seals. Replace modular
clutch assembly.
Excessive amount of grease applied to
input shaft splinesApply less grease to input shaft. Replace
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.
Cable self-adjuster mechanism sticking or
binding causing high preloadVerify that self-adjuster is free to move
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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
modular clutch assembly.
Leak at rear main or transaxle input shaft
sealReplace modular clutch assembly. Replace
seal.
Excessive heat from slippage Replace modular clutch assembly
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 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 modular clutch assembly
CLUTCH WILL NOT
DISENGAGE
PROPERLYDisc bent, distorted during transaxle
installationReplace modular clutch assembly
Clutch cover diaphragm spring damaged
during transaxle installationReplace modular clutch assembly
Release fork bent, loose, or damaged Replace fork if worn or damaged
Clutch cable binding or routed incorrectly Check and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable slackPull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL
MAKES REPEATED
ªPOPº NOISE IN
THE FIRST INCH
OF TRAVELSelf-adjusting mechanism in cable defective Replace clutch cable
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO
FLOORPedal bushings worn out or inadequate
lubricationReplace or lubricate bushings
Clutch pedal return spring worn out Lubricate or replace return spring
Clutch release lever pivot stud has
inadequate lubricationLubricate or replace clutch release lever
6 - 4 CLUTCHPL
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 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.
CLUTCH INTERLOCK/UPSTOP SWITCH
The clutch interlock/upstop switch is an assembly
consisting of two switches: an engine starter inhibit
switch (clutch interlock) and a clutch pedal upstop
switch (Fig. 5). The switch assembly is located in the
clutch/brake pedal bracket assembly (Fig. 6), each
switch being fastened by four plastic wing tabs.
CLUTCH INTERLOCK SWITCH
Mechanical Test
(1) With the park brake set and the transaxleIN
NEUTRAL,turn the ignition key to the start posi-
tion. The engine starter should not crank with the
clutch pedal at rest (not depressed). If the starter
cranks, proceed to the electrical test to determine
whether the switch is defective or the circuit is
shorted. If the vehicle does not crank, proceed to the
next step.
(2) With the park brake set and the transaxleIN
NEUTRAL,fully depress the clutch pedal and turn
Fig. 5 Clutch Interlock/Upstop Switch
1 ± UPSTOP SWITCH
2 ± INTERLOCK SWITCH
3 ± CONNECTOR
PLCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)