DODGE NEON 1999 Service Repair Manual

OIL PUMP-RECONDITION
NOTE: Also, check gear side clearance with a
straight edge and a feeler gauge (See Specifica-tions).
FRONT CLUTCH-RECONDITION
DISASSEMBLY
Fig. 84 Reaction Shaft Support Bolts
Fig. 85 Reaction Shaft Support
Fig. 86 Inner and Outer Pump Gears
Fig. 87 Measuring Pump Clearance (Gear to Pocket)
Fig. 88 Front Clutch Waved Snap Ring
21 - 78 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
To reassemble, reverse the above procedure.MEASURING PLATE CLEARANCE
REAR CLUTCH-RECONDITION
INSPECTION
Inspect facing material on all driving discs.
Replace discs that are charred, glazed, or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off, or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate and pres-
sure plate surface for burning, scoring, or damaged
driving lugs. Replace if necessary. Inspect plates and
discs for flatness; they must not be warped or cone-
shaped.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces; plates must travel freely in the
grooves. Note ball check in piston; be sure ball moves
freely. Inspect seal rings surfaces in clutch retainer
for nicks or deep scratches; light scratches will not
interfere with sealing of the seals. Inspect Neoprene
seal rings for deterioration, wear, and hardness.
Fig. 89 Thick Steel Plate and Waved Snap Ring
Fig. 90 Front Clutch (4-Disc Shown)
Fig. 91 Front Clutch Return Spring Snap Ring
Fig. 92 Front Clutch Return Spring and Piston
Fig. 93 Measuring Front Clutch Plate Clearance
PLTRANSAXLE 21 - 79
DISASSEMBLY AND ASSEMBLY (Continued)

Inspect piston spring and waved snap ring for distor-
tion or breakage.
Inspect Teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
0.061 to 0.063 inch. Replace if necessary.
DISASSEMBLY
Fig. 94 Rear Clutch Outer Snap Ring
Fig. 95 Rear Clutch (4-Disc Shown)
Fig. 96 Piston Spring Waved Snap Ring
Fig. 97 Rear Clutch Piston and Piston Spring
Fig. 98 Remove or Install Input Shaft Snap Ring
21 - 80 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Press out input shaft, if required.
ASSEMBLY
To reassemble, reverse the above procedure.
MEASURING PLATE CLEARANCE
FRONT PLANETARY AND ANNULUS GEAR-
RECONDITION
Fig. 99 Input Shaft Snap Ring
Fig. 100 Measuring Rear Clutch Plate Clearance
Fig. 101 Front Planetary Gear Snap Ring and No. 4
Thrust Washer (Always Install a New Snap Ring)
Fig. 102 Front Planetary Gear
Fig. 103 Annulus Gear Support Front Snap Ring
PLTRANSAXLE 21 - 81
DISASSEMBLY AND ASSEMBLY (Continued)

LOW/REVERSE (REAR) SERVO-RECONDITION
DISASSEMBLYASSEMBLY
To assemble, reverse the above procedure.
Fig. 104 Front Annulus Gear Support and Snap Ring
Fig. 105 Front Annulus Gear Support Snap Ring
Fig. 106 Low/Reverse Lever
Fig. 107 Low/Reverse Servo Snap Ring
Fig. 108 Remove Retainer, Spring and Servo
Fig. 109 Low/Reverse Servo Assembly
21 - 82 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ACCUMULATOR-RECONDITION
DISASSEMBLY
ASSEMBLY
To assemble, reverse the above procedure.
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION
DISASSEMBLY
ASSEMBLY
To assemble, reverse the above procedure.
TRANSFER SHAFT REPAIR
DISASSEMBLY
NOTE: Remove old sealant before applying new
sealant. Use MoparTRTV sealant, or equivalent,
when installing cover.
Fig. 110 Accumulator Snap Ring
Fig. 111 Accumulator Plate and Snap Ring
Fig. 112 Accumulator Spring and Piston
Fig. 113 Kickdown Servo Snap Ring
Fig. 114 Kickdown Servo Rod Guide and Snap Ring
PLTRANSAXLE 21 - 83
DISASSEMBLY AND ASSEMBLY (Continued)

STIRRUP AND STRAP REMOVAL
NOTE: A stirrup and retaining strap is attached to
the transfer gear. The stirrup prevents the transfergear retaining nut from turning and backing off the
transfer shaft. The strap is used to hold the stirrup
to the transfer gear and prevent the stirrup retain-
ing bolts from backing out.
(1) Using a punch, bend tabs on strap flat against
transfer gear.
(2) Remove bolts holding retaining strap to stir-
rup.
(3) Remove strap from transfer gear and stirrup.
(4) Remove stirrup from transfer gear.
Fig. 115 Kickdown Piston Return Spring and Piston
Fig. 116 Controlled Load Kickdown Servo
Fig. 117 Rear Cover Bolts
Fig. 118 Remove or Install Rear Cover
Fig. 119 Remove Transfer Shaft Gear Retaining Nut
21 - 84 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 120 Transfer Shaft Gear Nut and Washer
Fig. 121 Remove Transfer Shaft Gear
Fig. 122 Transfer Shaft Gear and (Select) Shim
Fig. 123 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 124 Install Transfer Shaft Gear Bearing Cone
Fig. 125 Governor Support Retainer
PLTRANSAXLE 21 - 85
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Remove or install both governor valves and
governor body.
Fig. 126 Remove Governor Support Retainer
Bearing Cup
Fig. 127 Install Governor Support Retainer Bearing
Cup
Fig. 128 Low/Reverse Band Anchor Pin
Fig. 129 Governor Assembly
Fig. 130 Transfer Shaft Bearing Snap Ring
Fig. 131 Remove Transfer Shaft and Bearing
Retainer Assembly
21 - 86 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 132 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
Fig. 133 Transfer Shaft and Bearing Retainer
Fig. 134 Remove Transfer Shaft Bearing Cone
Fig. 135 Install Transfer Shaft Bearing Cone
Fig. 136 Remove Transfer Shaft Bearing Cup
PLTRANSAXLE 21 - 87
DISASSEMBLY AND ASSEMBLY (Continued)