DODGE NEON 1999 Service Repair Manual

Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
Bearing Splitter P-334
Bearing Cone Remover 5048
21 - 118 TRANSAXLEPL
SPECIAL TOOLS (Continued)

Seal Remover 7794-a
Bearing Installer 5052
Bearing Cup Remover 6062-A
Bearing Installer 6536-A
Cooling System Tester 7700
PLTRANSAXLE 21 - 119
SPECIAL TOOLS (Continued)

TRANSAXLE
CONTENTS
page page
DESCRIPTION AND OPERATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM........................ 1
DIAGNOSIS AND TESTING
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM........................ 1REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) CABLE ASSEMBLY................ 2
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM ADJUSTMENT............ 4
DESCRIPTION AND OPERATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM
The Brake Transmission Shift Interlock (BTSI)
System, is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch. The BTSI system locks the shifter into the
PARK position. The BTSI system is engaged when-
ever the ignition switch is in the LOCK or ACCES-
SORY position.
An additional electrically activated feature will
prevent shifting out of the PARK position unless the
brake pedal is depressed at least one-half an inch. A
solenoid integrated with the BTSI cable assembly
(Fig. 1) is energized when the ignition switch is in
the RUN position. When the key is in the RUN posi-
tion and the brake pedal is depressed, the shifter is
unlocked and will move into any position. The BTSI
system also prevents the ignition switch from being
turned to the LOCK or ACCESSORY position, unless
the shifter is fully locked into the PARK position.
DIAGNOSIS AND TESTING
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM
If the ignition switch cannot be turned to the
LOCK position, with the shifter in PARK and the
brake pedal depressed, an adjustment of the Brake
Transmission Shift Interlock (BTSI) System may be
required. To adjust the Brake Transmission Shift
Interlock (BTSI) System, follow the procedure in the
Adjustment section of this group.
Fig. 1 BTSI Cable Assembly
PLTRANSAXLE 21 - 1

REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) CABLE ASSEMBLY
REMOVAL
(1) Disconnect and isolate, the battery negative (-)
cable from the vehicle battery.
(2) Remove console assembly. Refer to Group 23,
Body.
(3) Remove the gearshift knob set screw and knob.
(4) Remove the screws retaining the gearshift indi-
cator bezel and remove bezel and indicator lamp.
(5) Pry up the adjuster lock on the BTSI cable
assembly. Unsnap the BTSI cable assembly end fit-
ting from the groove in the gearshift mechanism (Fig.
2).
(6) Remove the cable core end from the plastic cam
of the shifter mechanism (Fig. 3) and pull the BTSI
cable out of the gear shift mechanism.
(7) Remove the steering column cover. Refer to
Group 8E, Instrument Panels and Systems for
Removal and Installation procedures.
(8) Remove the steering column cover liner. Refer
to Group 8E, Instrument Panel and Systems for
Removal and Installation Procedures.(9) Remove the three lower±to±upper shroud
attaching screws through the bottom of the lower
shroud and remove the lower shroud (Fig. 4).
(10) Turn the ignition to the RUN position.
Fig. 2 Brake Transmission Shift Interlock (BTSI)
Cable Assembly
Fig. 3 Gearshift Mechanism Plastic Cam
Fig. 4 Upper/Lower Shroud
21 - 2 TRANSAXLEPL

(11) Grasp the BTSI cable assembly clip and con-
nector. Remove the connector from the interlock
housing (Fig. 5).
(12) Disconnect the BTSI solenoid electrical con-
nector (Fig. 6).
(13) Unclip the BTSI cable assembly from the
retaining clip located within the wiring harness.
(14) Remove BTSI cable assembly from the dash
panel.INSTALLATION
CAUTION: When installing BTSI cable assembly,
care must be taken not to bend exposed cable wire
and slug at shifter end of cable.
(1) Route BTSI cable assembly into lower dash
panel.
(2) Install the BTSI cable assembly connector into
the interlock housing at the steering column (Fig. 7).
Verify the cable snaps into the housing.
(3) Install BTSI cable assembly into routing clip
located within the wiring harness.
(4) Route BTSI cable assembly to the console.
(5) Install the cable core end to the plastic cam of
the shifter mechanism. Snap the BTSI cable assem-
bly end fitting into the groove in the gearshift mech-
anism.
(6) Adjust the Brake Transmission Shift Interlock
(BTSI) System. See Brake Transmission Shift Inter-
lock (BTSI) System Adjustment, in this section.
(7) Check operation of the Brake Transmission
Shift Interlock (BTSI) System, as described in the
beginning of this section.
(8) Install console assembly. Refer to Group 23,
Body.
(9) Install screws retaining the gearshift indicator
bezel and install bezel and indicator lamp.
(10) Install the gearshift knob set screw and knob.
(11) Install two screws at the upper area of the
column liner and lower left corner.
Fig. 5 BTSI Cable Assembly Connector
Fig. 6 BTSI Solenoid
Fig. 7 BTSI Cable at Interlock Housing
PLTRANSAXLE 21 - 3
REMOVAL AND INSTALLATION (Continued)

(12) Position the lower shroud in place. Install the
three lower±to±upper shroud attaching screws
through the bottom of the lower shroud (Fig. 8).
(13) Reconnect the battery negative (-) cable to the
vehicle battery.
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM ADJUSTMENT
If ignition switch cannot be turned to the LOCK
position, with shifter in PARK, an adjustment of the
Interlock System may be required. To adjust the
Brake Transmission Shift Interlock (BTSI) System,
follow procedure listed below.
(1) Disconnect and isolate, the battery negative (-)
cable from the vehicle battery.
(2) Remove console assembly. Refer to Group 23,
Body.
(3) Remove the gearshift knob set screw and knob.
(4) Remove the screws retaining the gearshift indi-
cator bezel and remove bezel and indicator lamp.
(5) Reinstall the gearshift knob.(6) Place shifter in PARK.
(7) Turn ignition switch to the LOCK or ACCES-
SORY position. If cable has lost its adjustment, man-
ually position cable to get key into LOCK or
ACCESSORY position. Grasp slug on interlock cable
with needle nose pliers and pull back on cable. This
will allow the ignition switch to be turned to the
LOCK or ACCESSORY position.
(8) Check that the interlock cable slug is com-
pletely seated into the shifter interlock lever.
(9) Check that the ignition switch is still in the
LOCK or ACCESSORY position.
(10) Pry up the adjuster lock on the BTSI cable
(Fig. 9).
(11) Place a 1mm (0.040) shim between the larger
diameter portion of the shifter gate pin and the plas-
tic cam (Fig. 9).
(12) The spring on the BTSI cable should automat-
ically compensate for the slack in the adjuster.
(13) Snap down the interlock adjuster lock onto
the cable and remove the shim.
(14) After adjusting the BTSI system, check oper-
ation of the Brake Transmission Shift Interlock
(BTSI) System, as described in the beginning of this
section.
Fig. 8 Upper/Lower Shroud
Fig. 9 BTSI Cable Adjuster Lock
21 - 4 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

TIRES AND WHEELS
CONTENTS
page page
TIRES.................................. 1WHEELS................................ 8
TIRES
INDEX
page page
DESCRIPTION AND OPERATION
RADIAL-PLY TIRES....................... 2
REPLACEMENT TIRES.................... 3
SPARE TIRE±TEMPORARY................. 2
TIRE INFLATION PRESSURES.............. 2
TIRE INFORMATION...................... 1
TIRE PRESSURE FOR HIGH SPEED
OPERATION........................... 3
DIAGNOSIS AND TESTING
LEAD CORRECTION CHART................ 4
PRESSURE GAUGES..................... 3TIRE NOISE OR VIBRATION................ 4
TIRE WEAR PATTERNS.................... 3
TREAD WEAR INDICATORS................ 3
SERVICE PROCEDURES
REPAIRING TIRE LEAKS................... 4
TIRE AND WHEEL MATCH MOUNTING........ 6
TIRE AND WHEEL ROTATION............... 4
CLEANING AND INSPECTION
CLEANING TIRES........................ 7
SPECIFICATIONS
TIRE SPECIFICATIONS.................... 7
DESCRIPTION AND OPERATION
TIRE INFORMATION
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 1).
Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is not
always printed on the tire sidewall. The letterSindi-
cates that the tire is speed rated up to 112 mph.
²Qup to 100 mph
²Tup to 118 mph
²Uup to 124 mph
²Hup to 130 mph
²Vup to 149 mph
²Zmore than 149 mph (consult the tire manu-
facturer for the specific speed rating)
An All Season type tire will have eitherM+S,M
&SorM-S(indicating mud and snow traction)
imprinted on the side wall.
TIRE CHAINS
Refer to the owners manual supplied with this
vehicle to determine whether the use of tire chains is
permitted on this vehicle.
PLTIRES AND WHEELS 22 - 1

RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life and
ride quality, and decrease rolling resistance.
Radial-ply tires must always be used in sets of
four. Under no circumstances should they be used on
the front only. They may be mixed with temporary
spare tires when necessary. A maximum speed of 50
MPH is recommended while a temporary spare is in
use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
The use of oversized tires, either in the front or
rear of the vehicle, can cause vehicle drive train fail-
ure. This could also cause inaccurate wheel speed
signals when the vehicle is equipped with Anti-Lock
Brakes.
The use of tires from different manufactures on the
same vehicle is NOT recommended. The proper tire
pressure should be maintained on all four tires. For
proper tire pressure refer to the Tire Inflation Pres-
sure Chart provided with the vehicle.
SPARE TIRE±TEMPORARY
The temporary spare tire is designed for emer-
gency use only. The original tire should be repaired
or replaced at the first opportunity and reinstall. Donot exceed speeds of 50 MPH. Refer to Owner's Man-
ual for complete details.
TIRE INFLATION PRESSURES
Under inflation causes rapid shoulder wear, tire
flexing, and can result in tire failure (Fig. 2).
Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 3).
Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²The vehicle to drift.
For proper tire pressure specification refer to the
Tire Inflation Pressure Chart Placard provided with
the vehicle.
Tire pressures have been chosen to provide safe
operation, vehicle stability, and a smooth ride. Tire
pressure should be checked cold once per month.
Check tire pressure more frequently when the
Fig. 1 Tire Identification
Fig. 2 Under Inflation Wear
Fig. 3 Over Inflation Wear
22 - 2 TIRES AND WHEELSPL
DESCRIPTION AND OPERATION (Continued)

weather temperature varies widely. Tire pressure will
decrease when the outdoor temperature drops.
Inflation pressures specified on the placard are
always the cold inflation pressure of the tire. Cold
inflation pressure is obtained after the vehicle has
not been operated for at least 3 hours, or the vehicle
is driven less than one mile after being inoperative
for 3 hours. Tire inflation pressures may increase
from 2 to 6 pounds per square inch (psi) during oper-
ation. Do not reduce this normal pressure build-up.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING. THE TIRE CAN
FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
TIRE PRESSURE FOR HIGH SPEED OPERATION
Chrysler Corporation advocates driving at safe
speeds within posted speed limits. Where speed lim-
its allow the vehicle to be driven at high speeds, cor-
rect tire inflation pressure is very important. For
speeds up to and including 120 km/h (75 mph), tires
must be inflated to the pressures shown on the tire
placard. For continuous speeds in excess of 120 km/h
(75 mph), tires must be inflated to the maximum
pressure specified on the tire sidewall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.
REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommend that tires equivalent to the origi-
nal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires not listed in the specifica-
tion charts may cause interference with vehicle com-
ponents. Under extremes of suspension and steering
travel, interference with vehicle components may
cause tire damage.WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
PRESSURE GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.
TREAD WEAR INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 4).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
TIRE WEAR PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 5).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 5).
Fig. 4 Tread Wear Indicators
PLTIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)