Chrysler Neon 1995-1999 Repair Guide

Driven Disc and Pressure Plate

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Vehicles made at the Toluca assembly plant, in Mexico have conventional clutch and flywheel assembles. Vehicles made at the Belvidere assembly plant have modular clutch assemblies. As the removal procedures are different, refer to the Vehicle Identification Number (VIN) information, to determine where your vehicle was assembled.

REMOVAL & INSTALLATION



Toluca Built Vehicles

See Figures 1 through 11



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Fig. Fig. 1: Exploded view of the conventional clutch components-vehicles built in Toluca

  1. Remove the transaxle from the vehicle, as outlined earlier in this information.
  2.  
  3. Matchmark the position of the clutch cover and flywheel for proper alignment during installation.
  4.  
  5. Install a suitable clutch alignment tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings.
  6.  
  7. Loosen the clutch cover attaching bolts, one or two turns at a time, in a criss-cross pattern. This release the spring pressure gradually, avoiding cover damage.
  8.  

Do NOT touch the clutch disc facing with oily or dirty hands. Oil or dirt transferred from your hands onto the clutch disc may cause clutch chatter.

  1. Remove the clutch pressure plate, cover assembly and disc from the flywheel. Handle the components carefully to avoid contaminating the friction surfaces.
  2.  
  3. Inspect for oil leakage through the engine rear main bearing oil seal and transaxle input shaft seal. If there is leakage, it should be fixed at this time.
  4.  
  5. The friction faces of the flywheel and pressure place should not have excessive discoloration, burned areas, cracks, deep grooves or ridges. Replace parts as required.
  6.  
  7. Clean the flywheel face with medium sandpaper, then wipe the surface with mineral spirits. If the surface is severely scored, heat checked, cracked or warped, replace the flywheel.
  8.  



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 4: Check across the flywheel surface, it should be flat



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Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 7: Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts



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Fig. Fig. 8: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 9: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 10: You may want to use a thread locking compound on the clutch assembly bolts



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Fig. Fig. 11: Be sure to use a torque wrench to tighten all bolts

  1. The heavy side of the flywheel is indicated by a white paint mark, near the outside diameter. To minimize the effects of flywheel unbalance, perform the following installation procedure:
    1. Loosely assembly the flywheel to the crankshaft. If available, 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 leakage.
    2.  
    3. Rotate the flywheel and crankshaft until the white paint (heavy side) is at the 12 o'clock position.
    4.  
    5. Tighten the flywheel attaching bolts, in a criss-cross pattern, to 70 ft. lbs. (95 Nm).
    6.  

  2.  
  3. The clutch disc should be handled without touching the facings. Replace the disc if the facings show grease or oil soakage, or wear to within less than 0.008 in. (0.20mm) 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 the disc assembly should be dry, clean and not discolored from excessive heat. Each of the arched springs between the facings should be tight.
  4.  
  5. Wipe the friction surface of the pressure plate with mineral spirits.
  6.  
  7. Using a straight edge, check the pressure plate for flatness. The pressure plate friction area should be flat to slightly concave, with the inner diameter 0.000-0.001 in. (0.0-0.1mm) below the outer diameter. It should also be free from discoloration, burned areas, cracks, grooves or ridges.
  8.  
  9. Using a surface plate, test the cover for flatness. All sections around the attaching bolt holes should be in contact with the surface plate within 0.015 in. (0.381mm).
  10.  
  11. The cover should be a snug fit on the flywheel dowels. If the clutch assembly does not meet these requirements, it should be replaced.
  12.  

To install:
  1. Mount the clutch assembly on the flywheel with the disc centered on the alignment tool, being careful to properly align the dowels and the alignment marks made before removal. The flywheel side of the clutch disc is marked for proper installation. If the new clutch or flywheel is installed, align the orange cover balance spot as close as possible to the 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.
  2.  

  1. To avoid distorting the clutch cover, tighten the bolts gradually, a few turns at a time. Use a criss-cross pattern until all bolts are seated. Tighten the bolts to a final torque of 21 ft. lbs. (28 Nm).
  2.  
  3. Remove the clutch alignment tool.
  4.  
  5. Install the transaxle, as outlined earlier in this information.
  6.  

Belvidere Built Vehicles

See Figure 12

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter wiring, then remove the starter motor assembly.
  4.  
  5. Remove the rear and front transaxle brackets.
  6.  
  7. Unfasten the modular clutch assembly works.
  8.  
  9. Remove the transaxle from the vehicle, as outlined earlier in this information. The transaxle and modular clutch come out as an assembly.
  10.  
  11. Remove the modular clutch assembly from the transaxle input shaft. Handle the components carefully to avoid contaminating the friction surface.
  12.  
  13. Inspect for oil leakage through the engine rear main bearing oil seal and transaxle input shaft seal. If any leakage is noted, it should be fixed at this time.
  14.  



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Fig. Fig. 12: The transaxle and modular clutch are removed as an assembly

To install:

Always use new bolts when mounting the modular clutch assembly to the drive plate.

  1. Mount the modular clutch assembly onto the input shaft. Install the transaxle.
  2.  
  3. To avoid distorting the drive plate, tighten the bolts gradually a few turns at a time. Use a criss-cross pattern, until all bolts are seated. Tighten the bolts to a final torque of 55 ft. lbs. (75 Nm).
  4.  
  5. Install the clutch inspection cover.
  6.  
  7. Install the transaxle lower support brackets.
  8.  
  9. Install the starter assembly, then attach the wiring.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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