clutch DODGE NEON 2000 Service Owner's Manual

(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 18).
(25) Remove transaxle from vehicle (Fig. 18).
(26) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
(1) Inspect clutch release bearing and lever for
excessive wear and replace as necessary.
(2) Install clutch module onto input shaft. Install
transaxle into position.
(3) Install transaxle-to-engine mounting bolts (Fig.
18) and tighten to 95 N´m (70 ft. lbs.) torque.
(4) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (70 ft. lbs.) torque (Fig. 17).
(5) Remove screwjack.
(6) Install NEW drive plate-to-clutch module bolts
and progressively tighten all bolts in a criss-cross
pattern until the modular clutch assembly seats
against the drive plate. Final torque the bolts to 88
N´m (65 ft. lbs.) torque.
(7) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 16).
Fig. 13 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINIONFig. 14 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 15 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
6 - 10 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(8) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(9) Install bellhousing dust cover (Fig. 14).
(10) Install left engine-to-transaxle bending brace
(Fig. 14).(11) Install structural collar (Fig. 14) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(12) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 15).
(13) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(14) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(15) Lower vehicle.
(16) Connect vehicle speed sensor connector (Fig.
13).
(17) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 12).
(18) Connect clutch cable to fork and secure to
transaxle (Fig. 11).
(19) Install bellhousing cap (Fig. 11).
(20) Connect back-up lamp switch connector.
(21) Connect ground strap to transaxle upper
mount bracket.
(22) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
(23) Install the air cleaner/throttle body assy. as
follows:
(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(24) Connect the battery cables.
(25) Road test vehicle and inspect for leaks.
Fig. 16 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 17 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
PLCLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)

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.
INSTALLATION
(1) The pivot ball pocket in the fork, as well as the
fork arms should be lubricated with grease prior to
installation.
(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
Fig. 18 Transaxle Removal/Installation
1 ± MODULAR CLUTCH ASSEMBLY
2 ± CLIP3 ± TRANSAXLE
4 ± CLUTCH MODULE BOLT (4)
VIEW A
6 - 12 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

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.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Modular Clutch-to-Drive Plate Bolts..... 88N´m
(65 ft. lbs.)
Transaxle-to-Engine Mounting Bolts...... 95N´m
(70 ft. lbs.)
PLCLUTCH 6 - 13
CLEANING AND INSPECTION (Continued)

Radiator cooling fan control operation is accomplished
two ways. The fan always runs when the air condition-
ing compressor clutch is engaged. In addition to this
control, the fan is turned on by the temperature of the
coolant which is sensed by the coolant temperature sen-
sor which sends the message to the Powertrain Control
Module (PCM). The PCM turns on the fan through a
fan relay by grounding the relay's coil. The fan relay is
located in the Power Distribution Center (PDC) (Fig. 4).
Refer to the label beneath the PDC cover for location of
fan relay.
The PCM will actuate the fan relay whenever the A/C
clutch is engaged regardless of coolant temperature and
vehicle speed. If the A/C clutch is not engaged, the PCM
will actuate the fan relay when the coolant temperature
reaches approximately (97É C) 207É F and turns off the
fan relay when the coolant temperature drops to
approximately (94ÉC) 201É F. The fan relay is also
turned off when the vehicle speed is above approxi-
mately 100 Km/h (62 MPH). Refer to Group 8W, Wiring
Diagrams for circuity provided.
If the cooling fan is inoperative or a Diagnostic
Trouble Code (DTC) related to fan control has been
set, refer to the appropriate Powertrain Diagnostic
Manual for complete diagnostic procedures.
COOLING SYSTEM PRESSURE CAP
The cooling system pressure cap is located on the cool-
ant outlet housing near the front of the cylinder head.
The cooling system will operate at higher than atmo-
spheric pressure. The higher pressure raises the coolant
boiling point, allowing increased radiator cooling capac-
ity. The pressure cap will release cooling system pres-
sure in a range of 97±124 kPa (14±18 psi).
A vent valve located in the center of the cap allows
a small amount of coolant flow from the coolant
reserve system (CRS) tank. This valve is spring
loaded in the closed position. However, it must be
free to open during system cool-down.If the valve is
stuck shut, the radiator hoses will collapse on
cool-down. Clean the vent valve (Fig. 5) to
ensure proper sealing function.
There is a gasket in the cap that seals to the top of
the filler neck so that vacuum is maintained to draw
coolant back into the system from the coolant reserve
system (CRS) tank.
Fig. 4 Power Distribution Center (PDC)
RADIATOR COOLING FAN OPERATION CHART
Cooling Fan Control
A/C Off
Fan On: 97É C (207É F)
Fan Off: 94É C (201É F)Vehicle Speed >
100 Km/h (62
MPH)
A/C On
Fan OnÐregardless of coolant temperature or vehicle
speed.
Fig. 5 Cooling System Pressure Cap
1 ± PRESSURE RATING
2 ± FILLER NECK SEAL
3 ± PRESSURE VALVE
4 ± VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
7 - 4 COOLING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

STARTING SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
SUPPLY CIRCUIT AND CONTROL CIRCUIT.....1
DESCRIPTION AND OPERATION
STARTER MOTOR.........................1
DIAGNOSIS AND TESTING
CONTROL CIRCUIT........................2
FEED CIRCUIT RESISTANCE................3
FEED CIRCUIT...........................5STARTING SYSTEM.......................6
REMOVAL AND INSTALLATION
SAFETY SWITCHES.......................8
STARTER MOTOR.........................8
STARTER RELAY.........................8
SPECIFICATIONS
STARTER MOTOR.........................9
TORQUE................................9
GENERAL INFORMATION
INTRODUCTION
The starting system (Fig. 1) and (Fig. 2) has:
²Ignition switch
²Starter relay
²Park/Neutral Starting Back-Up Lamp Switch
with automatic transmissions
²Clutch Interlock/Upstop Switch with manual
transmissions
²Powertrain Control Module (PCM) for double
start over ride
²Wiring harness
²Battery
²Starter motor with an integral solenoid
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The Powertrain Control Module (PCM) controls a
double start over ride safety that does not allow thestarter to be engaged if the engine is already run-
ning.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate cir-
cuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
DESCRIPTION AND OPERATION
STARTER MOTOR
The starter is a permanent magnet starter motor.
The fields have six permanent magnets. A planetary
gear train transmits power between starter motor
and pinion shaft. The starter provides mechanical
torque to rotate the crankshaft at an RPM (crank
speed) necessary for self-sustained spark/ignition.Fig. 1 Starting System Components - Automatic
Fig. 2 Starting System Components - Manual
PLSTARTING SYSTEMS 8B - 1

DIAGNOSIS AND TESTING
CONTROL CIRCUIT
The starter control circuit has:
²Starter solenoid
²Starter relay
²Park/Neutral Starting and Back-Up Lamp
Switch with automatic transmissions
²Clutch Interlock/Upstop Switch with manual
transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Double Start Override algorithm located in the
PCM
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the in the Power Distribution Center
(PDC). Refer to the PDC cover for the proper relay
location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.
(3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(5) Lower the vehicle.
(6) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(7) Connect a starter switch or a jumper wire
between the remote battery positive post and termi-
nal 87 of the starter relay connector.
(a) If engine cranks, starter motor and starter
solenoid is good. Go to the Starter Relay Test.(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Check for corroded connections at starter termi-
nals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
Use the Starter Relay Pin Call-Out table and (Fig. 3)
for relay testing.
Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 7565 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 86 and
a ground lead to terminal 85 to energize the relay.
The relay should click. Test for continuity between
terminals 30 and 87, and no continuity between ter-
minals 87A and 30. If OK, refer to Relay Circuit Test
procedure. If not OK, replace the faulty relay.
Fig. 3 Starter Relay
8B - 2 STARTING SYSTEMSPL

STARTER RELAY PIN CALL-OUT
PIN CIRCUIT COLOR DESCRIPTION
1 (86) A041 YL IGNITION SWITCH OUTPUT (START)
2 (85) K090 TN PCM
3 (30) A001 RD FUSED B+
4 (87A) NOT USED
5 (87) T040 BR STARTER SOLENOID
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the START position. On
vehicles with a manual transmission, the clutch
pedal must be fully depressed for this test. Check for
battery voltage at the cavity for relay terminal 86
with the ignition switch in the START position, and
no voltage when the ignition switch is released to the
ON position. If OK, go to Step 5. If not OK with an
automatic transmission, check for an open or short
circuit to the ignition switch and repair, if required.
If the circuit to the ignition switch is OK, see the
Ignition Switch Test procedure in this group. If not
OK with a manual transmission, check the circuit
between the relay and the clutch interlock/upstop
switch for an open or a short circuit. If the circuit is
OK, refer to the Clutch Interlock/Upstop Switch
Diagnosis and Testing in Group 6-Clutch.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the PCM only when the gearshift selector
lever is in the Park or Neutral positions. On vehicles
with a manual transmission, it is grounded through
the PCM when the clutch pedal is depressed. Check
for continuity to ground at the cavity for relay termi-
nal 85. If not OK, check for an open or short circuit
to the park/neutral starting and back-up lamp
switch, or the clutch interlock/upstop switch. Repair,
as necessary. If the circuit is OK, refer to the Park/Neutral Starting and Back-Up Lamp Switch Removal
and Installation in Group 21-Transaxle. Testing is
located within the Removal and Installation proce-
dures.
SAFETY SWITCHES
For diagnosis of:
²Clutch Interlock/Upstop Switch, refer to Diagno-
sis and Testing in Group 6-Clutch.
²Park/Neutral Starting and Back-Up Lamp
Switch, refer to Removal and Installation in Group
21-Transaxle. Testing is located within the Removal
and Installation procedures.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Check all wiring for opens or
shorts, and all connectors for being loose or corroded.
Refer to Group 8D-Ignition Systems, or Group
8W-Wiring Diagrams.
BATTERY
Refer to Group 8A-Battery for Diagnosis and Test-
ing of the battery.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W-Wiring Diagrams.
FEED CIRCUIT RESISTANCE
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown (ASD) Relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
PLSTARTING SYSTEMS 8B - 3
DIAGNOSIS AND TESTING (Continued)

FEED CIRCUIT
The following procedure will require a suitable
volt-ampere tester (Fig. 8).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 9). Refer to the operating instructions
provided with the tester being used.(2) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown (ASD) Relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
position or with the clutch pedal depressed and SET
parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
8).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²If voltage is below 9.6 volts and amperage draw
is above 300 amps, the problem is the starter.
Replace the starter. Refer to Starter Removal and
Installation in this section.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect the ASD relay. Start the vehi-
cle several times to assure the problem has been cor-
rected.
Fig. 7 Battery Positive Cable Resistance
1 ± VOLTMETER
Fig. 8 Volt Ampere Tester - Typical
Fig. 9 Volt-Ampere Tester Connections - Typical
1 ± POSITIVE CLAMP
2 ± NEGATIVE CLAMP
3 ± INDUCTION AMMETER CLAMP
PLSTARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM
For circuit descriptions and diagrams, refer to
8W-21, Starting System in Group 8W-Wiring Dia-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Group 8A-Battery
for more information.²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Clutch Interlock/Upstop Switch- Visually
inspect the clutch interlock/upstop switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Park/Neutral Starting and Back-Up Lamp
Switch- Visually inspect the park/neutral starting
and back-up lamp switch for indications of physical
damage and loose or corroded wire harness connec-
tions.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
²Starter Motor- Visually inspect the starter
motorfor indications of physical damage and loose or
corroded wire harness connections.
²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
8B - 6 STARTING SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)