DODGE NEON 2000 Service Repair Manual

DISASSEMBLY AND ASSEMBLY
TRANSAXLE
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
CAUTION: The transaxle output shaft is serviced as
a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench.
(2) Remove the clutch release bearing and fork.
Move the release fork and bearing to an in-line posi-
tion. Grasp the release lever with two hands in the
pivot stud socket area. Pull with even pressure to
release the fork from the pivot stud.
CAUTION: Do not use a screwdriver or pry bar to
release the fork as this may cause damage to the
fork and/or clip.
(3) Remove shift levers by driving out the roll pins.
(4) Remove transaxle case half bolts (Fig. 46).
(5) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 47). Separate
the case halves (Fig. 48).
Fig. 46 Case Bolts
1 ± CASE BOLTS
Fig. 47 Transaxle Case Halves
1 ± BELLHOUSING HALF
2 ± GEAR CASE HALF
Fig. 48 Separate Case Halves
1±PRYTOOL
2 ± CASE HALVES
3 ± PRY SLOT
21 - 18 TRANSAXLEPL

(6) Remove bellhousing half from gear case half
(Fig. 49).
(7) Remove output shaft roller bearing from output
shaft.
(8) Remove differential assembly (Fig. 50).(9) Remove reverse idler shaft bolt (Fig. 51).
(10) Remove reverse idler shaft (Fig. 52).
Fig. 49 Bellhousing Case Half Removal
1 ± BELLHOUSING CASE HALF
2 ± DIFFERENTIAL
3 ± GEAR CASE HALF
Fig. 50 Differential Assembly Removal
1 ± INPUT SHAFT
2 ± OUTPUT SHAFT
3 ± DIFFERENTIAL
4 ± CASE
Fig. 51 Reverse Idler Shaft Bolt Removal
1 ± CASE
2 ± REVERSE IDLER SHAFT
3 ± REVERSE IDLER SHAFT BOLT
Fig. 52 Reverse Idler Shaft Removal
1 ± REVERSE IDLER SHAFT
PLTRANSAXLE 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Remove reverse idler gear and spacer (Fig.
53).
(12) Remove two screws retaining reverse fork
bracket (Fig. 54). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 55).(13) Using snap±ring pliers, remove selector shaft
spacer (Fig. 56).
(14) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 57).
Fig. 53 Reverse Idler Gear and Spacer Removal
1 ± SPACER
2 ± REVERSE IDLER GEAR
Fig. 54 Screws Retaining Reverse Fork Bracket
1 ± SCREWS (2)
2 ± REVERSE FORK BRACKET
Fig. 55 Remove Reverse Fork Bracket
1 ± REVERSE FORK BRACKET
2 ± REVERSE CAM BLOCKOUT
3 ± SHIFT BLOCKER ASSEMBLY
Fig. 56 Remove Selector Shaft Spacer
1 ± SHIFT BLOCKER ASSEMBLY
2 ± SELECTOR SHAFT SPACER (PLASTIC)
3 ± SNAP RING PLIERS
21 - 20 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(15) Remove transaxle end cover (Fig. 58) (Fig.
59).(16) Remove two snap rings retaining the output
shaft and the input shaft to the bearings (Fig. 60).
Fig. 57 Selector Shaft
1 ± SHIFT ASSEMBLY
2 ± SELECTOR SHAFT
Fig. 58 Transaxle Cover Removal
1 ± TRANSAXLE CASE
2 ± END COVER
Fig. 59 End Cover
1 ± END COVER
2 ± CASE
Fig. 60 Snap Rings Retaining Bearings
1 ± SNAP RING PLIERS
2 ± SNAP RINGS
PLTRANSAXLE 21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)

(17) Using bench fixture and shims provided (Mill-
er tools # 6785, 6785-1, and 6785-2), turn transaxle
over. Install transaxle onto bench fixture (Fig. 61).
Verify shim spacers are in position on bench fixture.
Install transaxle into shop press.
(18) Install bearing fixture Miller tool #6768 onto
transaxle end bearings (Fig. 62). Verify tool is prop-
erly aligned to input and output shafts.
CAUTION: The oil dams in the input and output
shafts can be damaged while pressing on the
shafts if the bearing fixture is not used properly.(19) Install transaxle gear case into shop press.
Press output and input shaft assemblies out of case
(Fig. 63).
(20) Remove transaxle from press.
(21) Carefully remove transaxle case from the
shaft assemblies and bench fixture (Fig. 64). Be sure
the oil±feed trough to the end bearings is not dam-
aged (Fig. 65).
Fig. 61 Bench Fixture
1 ± SHIMS
2 ± TRANSAXLE
3 ± 6785 BENCH FIXTURE
Fig. 62 Bearing Fixture
1 ± BEARING FIXTURE
2 ± TRANSAXLE CASE
Fig. 63 Pressing Gears Out of Case
1 ± BEARING FIXTURE
2 ± PRESS RAM
3 ± TRANSAXLE CASE
4 ± BENCH FIXTURE
Fig. 64 Transaxle Case Removal
1 ± TRANSAXLE CASE
2 ± BENCH FIXTURE
3 ± GEARTRAIN
21 - 22 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(22)TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim,
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 66) (Fig. 67) (Fig. 68)
(Fig. 69) (Fig. 70).TRANSAXLE W/O REVERSE
BRAKE:Remove plastic spacer from the input shaft
assembly.
Fig. 65 Oil Feed Trough
1 ± OIL FEED TROUGH
Fig. 66 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 67 Reverse Brake Friction Cone
1 ± REVERSE BRAKE FRICTION CONE
Fig. 68 Reverse Brake Blocking Ring
1 ± REVERSE BRAKE BLOCKING RING
Fig. 69 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

(23) Remove the shift blocker assembly from the
bench fixture (Fig. 71).
(24) Remove the 1-2 shift fork from the output
shaft (Fig. 72).
(25) Remove input and output shaft assemblies
from bench fixture (Fig. 73).CAUTION: The output shaft assembly is serviced
as an assembly. Do not try to repair any component
on the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the complete output
shaft assembly.
Fig. 70 Reverse Brake Race
1 ± REVERSE BRAKE RACE
Fig. 71 Shift Blocker Removal
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 72 1±2 Shift Fork Removal
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 73 Gear Train Removal
1 ± 6785 BENCH FIXTURE
2 ± INPUT AND OUTPUT SHAFTS
21 - 24 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end plate cover is
MopartRTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 74).
(2) Install shift rails and forks into bench fixture
(Fig. 75).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 76).
(4) Install reverse brake race onto input shaft (Fig.
77).
(5) Install reverse brake needle bearing (Fig. 78).
Fig. 74 Bench Fixture
1 ± BENCH FIXTURE
2 ± GEARTRAIN
Fig. 75 Shift Rail Installation
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 76 Shift Blocker Installation
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 77 Reverse Brake Race Installation
1 ± REVERSE BRAKE RACE
Fig. 78 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(6) Install reverse brake blocking ring (Fig. 79).
(7) Install reverse brake friction cone (Fig. 80).(8) Install reverse brake shim (Fig. 81). Apply
petroleum jelly to shim to hold in place.
(9) Install gear±case half over bench fixture (Fig.
82). Line up shift finger over 3-4 lug.
Fig. 79 Reverse Brake Blocking Ring Installation
1 ± REVERSE BRAKE BLOCKING RING
Fig. 80 Reverse Brake Friction Cone Installation
1 ± REVERSE BRAKE FRICTION CONE
Fig. 81 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 82 Gear Case Half
1 ± TRANSAXLE CASE
2 ± BENCH FIXTURE
3 ± GEARTRAIN
21 - 26 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(10) Line up reverse brake friction cone lugs to the
slots in the gear case (Fig. 83). Verify reverse brake
shim is in position.
(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 84).(12) Install shaft snap rings at input and output
bearings (Fig. 85).
(13) Apply MopartRTV sealant to end±cover outer
edge and around bolt holes. Install end±cover onto
gear case. Tighten end cover bolts to 29 N´m (21 ft.
lbs.) torque (Fig. 86).
Fig. 83 Friction Cone Lugs
1 ± CASE
2 ± FRICTION CONE LUGS
3 ± INPUT SHAFT
Fig. 84 Installing Input and Output Bearings
1 ± INPUT AND OUTPUT BEARINGS
2 ± SPECIAL TOOL C-4992-1
Fig. 85 Snap Rings Retaining Bearings
1 ± SNAP RING PLIERS
2 ± SNAP RINGS
Fig. 86 Transaxle End Cover
1 ± TRANSAXLE CASE
2 ± END COVER
PLTRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)