Clutch Pedal - Squeak/Creak/Chirp Noises
NO: 06-02-94GROUP: Clutch
EFFECTIVE DATE: Sep. 2, 1994
SUBJECT:
Noise When Operating Clutch Pedal
MODELS:
1995 (PL) Neon
(FJ) Talon (Non Turbo Equipped)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE.
SYMPTOM/CONDITION:
There are two possible noise sources that may be encountered while operating the clutch pedal.
1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature.
2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures.
DIAGNOSIS:
CONDITION 1:
Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever.
CONDITION 2 - Neon Only
Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release.
Perform the appropriate repair for the specific condition encountered.
PARTS REQUIRED: (Condition 1)
1 4796664 Throwout Lever and Pivot Package 1995 Neon
1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo
AR 4318063 Mopar Multi-Purpose Grease
AR 4318031 Mopar Lock N' Seal
PARTS REQUIRED: (Condition 2 - Neon Only)
1 4670400 Cable Assembly - Clutch Release
TOOLS REQUIRED: (Condition 1)
Slide Hammer Miller Tool # C-3752
Pivot Remover/Installer Tool Miller Tool # 6891
REPAIR PROCEDURE: (Condition 1)
This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot.
1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the transaxle from the vehicle.
Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle.
2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever.
3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot.
4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2).
NOTE:
APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING.
5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063.
6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4).
7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure.
8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4.
Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6.
REPAIR PROCEDURE: (Condition 2 - Neon Only)
This procedure involves replacing the Clutch Release Cable Assembly.
Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Condition 1
Labor Operation No: 06-40-10-96 Neon 2.6 Hrs.
Talon 2.8 Hrs.
FAILURE CODE: P8 - New Part
Condition 2 - Neon Only
Labor Operation No. 06-50-15-92 0.4 Hrs.
FAILURE CODE: P8 - New Part