How To: Daniel's PT Clutch Swap 03 Neon R/T

danman132x
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How To: Daniel's PT Clutch Swap 03 Neon R/T

Post by danman132x » Wed Nov 05, 2008 11:30 pm

Well I'm finally getting all the pieces together, and my clutch swap is coming right around the corner. I will be doing it on Sunday, Nov. 16th. I will attempt to take many pictures during the swap, and also while doing the rear main seal, because I have searched the net and can't find any clutch swap links on Neons, so I will be doing this for myself, and for the benefit of future clutch swappers who need a lil info.

Here are some pictures of my PT clutch itself.
Backside with the 4 bolt holes.
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Quick side shot of the assembly
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Upper views (yellowish hues are pictures I took without the flash)
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closer up, of the fingers
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one of my favorite shots I took of it
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My throwout bearing, part 4670026AB
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mock up with no purpose...
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Flexplate to modular clutch assemble bolts, part #6504383
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Rear Main Seal Part #4621939AB
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Group shot of a few items so far, including one quart of Mopar ATF+4 (I have the rest...) Rear Main Seal, Transmission Mount Insert, Belts for the Alt. and PS/AC which I'm going to do also, clutch, and TOB.
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In some pictures you can see that my clutch is a lil dusty looking. Pics 7 and 9 down you can tell a lil. This is some sort of packaging dust or from sitting on the shelf too long. I used some compressed air and got most of it off, and I'm hoping this wont affect the clutch itself.

I also have 8 Flexplate to crankshaft bolts, part 6503465, that are awaiting pickup from the dealership.

A whole lot more to come, especially once the job is done. Thanks for looking so far.
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latief
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Post by latief » Thu Nov 06, 2008 9:24 am

Nice,

where did you get the tranny-mount inserts from?

danman132x
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Post by danman132x » Thu Nov 06, 2008 1:18 pm

I got the insert from Vitors site, www.neongoodies.com , but they also sell them on http://polybushings.com/
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danman132x
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Post by danman132x » Sun Nov 16, 2008 9:15 pm

Here are some pics of me starting the clutch swap.

Front passenger side hub/brake assembly. Popping off the big bracket from the hub assembly was a PITA.
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Top view of the transmission before taking off
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Axles have been removed, you can see through the tranny. Pulled the damn plug before all this, and fluid came gushing out making a mess
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Passenger side axle
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More pics of the brake/hub assemble after pulling out the axle. The axle slid right out, no problem at all. Axle used a 32mm socket to remove. Some of the rubber parts are pretty damaged looking, but I dont have the parts to replace those without taking it to a shop.
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Engine supported by the oil pan and some wood blocks
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First view of the flexplate after removing tranny
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The tranny itself, nothing wiped down yet inside
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The shaft where the TOB sits was dry as a bone, and pretty nasty. When I put my new TOB on it, I cleaned it up well, and lubed the shaft where it slides with some moly based grease
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Old throw out bearing. Was Nasty and lots of play it in, after 58000 miles
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Stock clutch assembly
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Tranny after small wipe down and shaft cleaned some, but not lubed yet
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Flexplate removed
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Crank and rear main seal
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Removed the old rear main seal. It was in there TIGHT, and still in great shape... until I removed it. Damaged it bad removing it, but taking care not to damage the seal surface on the block itself
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Me under the car
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New rear main seal in place. Talk about a Pain in the A**. It took about 30 mins to do, because I didnt have the proper install tool, and it has to be hit in on all sides evenly. There is no tolercance at all. If one side was in a little more than the opposite, it would not go in. I finally got it... Used the old RMS, block of wood, and kept trying to hit it evenly in. Still took some trial and error..
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Flexplate again
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ring that goes with flexplate
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old clutch, new clutch, flexplate
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old and new..
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Misc pic of my aftermarket oil pressure sensor
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Getting the new clutch bolted up. Pic is near oil pan
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Some random box, dont know what it is. Says AT Controler I think
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Looking up at the O2 sensor
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New clutch in place
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Tranny with new TOB in place
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Tranny back on, and other booger bushing in place. Didnt use it before because the post was so rusted it made the shifter stuck in place. I sanded it some and applied some lube
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I still have to double check all connections, put the drivers side axle back in (fell apart other day and had trouble with the clamp), and go for my first test drive with it. I have felt the pedal, and it is lighter than the stock clutch, but not like some people say having almost no feel at all. I won't truly know until I go out for my drive. It wasn't a hard job doing it for the first time, but pretty time consuming with certain things and snags.

I pray my rear main seal will not leak. I had no problems with my old one, but since I was down there I changed it out.
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Danteneon
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Post by Danteneon » Mon Nov 17, 2008 10:30 am

Great write-up man! Looks like everything went smoothly for you :thumbup:
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Post by ZeroChad » Mon Nov 17, 2008 10:43 am

Thanks for posting this, its very informational! So the PT clutch is modular like the stock one? Let us know how if feels after driving it more.
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Post by NickKo » Mon Nov 17, 2008 2:04 pm

Great write up, and great pics ! :thumbup: Thanks for posting this up !!



ZeroChad wrote:So the PT clutch is modular like the stock one?
Yes, Exactly....

- Nick
-1998 2-dr SOHC MTX= 57mm TB; Maddog STS
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Post by occasional demons » Mon Nov 17, 2008 2:06 pm

:thumbup: Nice! I like the built in cooling fan on the PT assembly.
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Post by danman132x » Tue Nov 18, 2008 11:20 am

Here are a few more pictures.

Car just chillin in the garage
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Finally a picture showing the midpipe where my resonator was cut out and replaced with a straight pipe
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random picture of the cylinder
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PCM
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new tail lights and clear third brake light I also installed after the clutch
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I went for my first test drive, and the clutch feels great so far. I am in the process of breaking it in, so I won't have any "hard" driving experiance with it yet. The clutch is very smooth, and I'm still getting used to the lighter pedal feel. (as of now, 11-18 through 11-19, the car is in the shop for an oil leak on the timing belt side :( )
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Post by LilSparkPlug » Tue Nov 18, 2008 1:19 pm

BFG G-Force sports! Great tires...I <3 them! Nice work looks like everything went smoothly for you. :)

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Post by danman132x » Thu Dec 11, 2008 2:53 am

Just a quick update, I finally have about 500 miles on it, and I got on it hard a few times, and I have to say it grips like crazy compared to my stock clutch. I can finally chirp 2nd gear again easily. The clutch feels good, although I am still getting used to the "snappier" engagement. It's almost as if the engagement point has a smaller point where it grabs. The clutch is usually much smoother in the morning when the car is cold, but every now and then it still chatters until warmed up, just like the stock clutch. The tranny noise is still there ever since I installed the clutch, and I have a feeling it's the same kind of noise BRR and Mad_Mediros(spelling) had, although not as loud. I'm pretty satisfied with the clutch, and unless the noise gets louder, I'll just get used to it.
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Post by danman132x » Tue Feb 17, 2009 11:28 pm

Clutch update! I have about 2500 miles on the clutch now. Still working flawlessly. It grips like a champ. I can even manage to get a slight chirp out of third gear sometimes. The rattling noise... still there unfortunately, but it's not any worse than right after the install. I really think it's the clutch itself and not the transmission. Could be the lil yellow springs, bigger springs on the clutch disk itself, or some other part of the clutch. Every now and then, there is some chatter in the mornings, mostly if it's been really humid outside. Couple starts and it's smooth as butter for the whole day. Feel free to use any pics for the FAQ section.
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Post by Fuzzyneon » Tue Feb 17, 2009 11:37 pm

wish i had the balls to try to swap my clutch im scared too never did it before =(
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danman132x
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Post by danman132x » Tue Feb 17, 2009 11:54 pm

Neither did I. I got the digital copy of the FSM from a site we are no longer allowed to link, and some help on here and from my dad, and it went pretty smooth. I'm sure you could do it no problem.
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Post by Fuzzyneon » Wed Feb 18, 2009 12:34 am

i lack a garage! lol i may try with some help looks great ill be using youre pics to guide to also!
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Post by BlackRoseRacing » Thu Feb 19, 2009 4:58 am

trani noise in the morning?
for the heck of it:
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dgodard
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Post by dgodard » Sun Feb 22, 2009 2:06 pm

What brand is mopar clutch? It says Luk or sachs on it???
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danman132x
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Post by danman132x » Sun Feb 22, 2009 2:09 pm

It's a LUK clutch. Both the stock and the PT stock clutch
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Post by Arro » Tue Feb 24, 2009 1:29 pm

Ok, I'm confused about something here, I was just reading on the other 'org that the PT non-GT clutch (or whatever...?) is the same as our clutches... but obviously your pictures show differently.

So two questions, first, what *specific* vehicle is this clutch out of, and second, MPx claims it's only good for another 50-75hp, have any of you used this clutch with more? (think turbo kit power output)

I' have just about everything for my MTX swap except the clutch, and I'd like to pick one now... I take it MPx is a good source for this...?
Drive it like you stole it, and work on it like you married it.
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Post by danman132x » Wed Feb 25, 2009 10:37 am

Arro wrote:Ok, I'm confused about something here, I was just reading on the other 'org that the PT non-GT clutch (or whatever...?) is the same as our clutches... but obviously your pictures show differently.

So two questions, first, what *specific* vehicle is this clutch out of, and second, MPx claims it's only good for another 50-75hp, have any of you used this clutch with more? (think turbo kit power output)

I' have just about everything for my MTX swap except the clutch, and I'd like to pick one now... I take it MPx is a good source for this...?
The non mod PT clutch is not the same as the stock. It is the one I swapped to. I don't know the specific years, but it is a PT Cruiser Clutch from the non turbo models. I bought mine from modernperformance.com and is a direct replacement. I also went ahead and bought new bolts for the flywheel and clutch from the dealership just to be safe. I replaced the rear main seal while in there.
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Post by Arro » Wed Feb 25, 2009 12:47 pm

A direct replacement.... ok yes or no, this is an *upgrade* over the stock clutch, and offers more grab?

I am still also confused about the modular vs. non-modular thing... I had thought that all 2GN and PT clutches were modular. Am I wrong?
Drive it like you stole it, and work on it like you married it.
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Post by hul kogan » Wed Feb 25, 2009 1:54 pm

Arro wrote:A direct replacement.... ok yes or no, this is an *upgrade* over the stock clutch, and offers more grab?
Yes, this is considered an upgrade over the stock piece.
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Post by ragek23 » Wed Feb 25, 2009 9:13 pm

I got that same clutch from modern. It lasted me about 18months before it blew into pieces on the autox track.

I dont' know what clutch I have in now but the transmission shop put in another type of performance clutch and its holding up much better.

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Post by NeonOn19s » Wed Feb 25, 2009 10:19 pm

nice write up.
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Post by danman132x » Wed Feb 25, 2009 11:11 pm

ragek23 wrote:I got that same clutch from modern. It lasted me about 18months before it blew into pieces on the autox track.

I dont' know what clutch I have in now but the transmission shop put in another type of performance clutch and its holding up much better.
ouch. Thats not good to hear. :(
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Post by Arro » Thu Feb 26, 2009 12:24 am

Yeah I'm kinda concerned about clutch choice, some of those other ones are rediculously priced.... but I don't want something that's going to fail, either.
Drive it like you stole it, and work on it like you married it.
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Post by ragek23 » Thu Feb 26, 2009 11:12 pm

Well i am 0for1 on the mopar performance clutch and I will never buy another again. Maybe next time I will go for the fidanza kit w/flywheel.

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Post by BlackRoseRacing » Fri Feb 27, 2009 3:49 am

To clarify things:
1994/1995 Dodge Neon = Conventional clutch,pressure plate, flywheel
1996-2009 Dodge Neon/Chrysler PT Cruiser = Modular Clutch
As for the PT/Mopar LUK clutch explosio, IDK in N/A form mine has been in the car for a year now with no issues, but I have not Auto-X'd the car yet either :lol:

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Post by D-Railed_Neon » Tue Jun 26, 2012 2:42 pm

Post resurrection and request for how to sticky. Please and thank you
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speed127
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Post by speed127 » Tue Jun 26, 2012 5:34 pm

also a quick note, mopar clutches are made by sachs not luk
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