torque DODGE NEON 1999 Service Repair Manual

²Dings or dents in the corrugations of the cou-
pling or anywhere else on the coupling wall.
²A bend in the corrugated section of the cou-
pling.
If any of the preceding conditions exist the steering
couplingMUSTbe replaced.
The steering gear must be removed from the vehi-
cle to allow access for replacement of the lower cou-
pling. Refer to Steering Gear Service Procedures in
this group of the service manual for the required
steering gear removal procedure.
(5) If lower coupling does not require replacement,
install steering column upper coupling silencer seal
(Fig. 4) back on the vehicle.
(6) Ensure front wheels of vehicle are positioned
straight-ahead and then align and attach steering
column upper coupling to lower coupling (Fig. 3).
Install the coupling pinch bolt (Fig. 3). Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).Be
sure to install upper to lower steering coupling
pinch bolt safety pin (Fig. 3).REMOVAL AND INSTALLATION
STEERING COLUMN SERVICE PROCEDURE
WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times
when working on steering columns.
CAUTION: Disconnect negative (ground) cable
from the battery, before servicing any column com-
ponent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
Fig. 5 Steering Column Coupling Inspection
PLSTEERING 19 - 37
DIAGNOSIS AND TESTING (Continued)

(23) Remove steering column from vehicle through
the drivers door of the passenger compartment. Use
care to avoid damaging the paint or interior trim.
INSTALL
(1) Install steering column into steering column
access opening in lower instrument panel.
(2) Install the vehicle wiring harness connectors,
into the ignition switch and clock spring assembly
(Fig. 19).
(3) Install vehicle wiring harness connectors into
multi-function switch and turn signal switch (Fig. 18)
on steering column assembly. Install routing clip
(Fig. 18) holding wiring harness to jacket of steering
column.
(4) Install the studs in the steering column sup-
port bracket, into the slots in the aluminum capsules
in the upper mounting bracket of the steering column
(Fig. 17). Partially install the 2 upper steering col-
umn assembly mounting bracket to support bracketattaching nuts (Fig. 17).Do not tighten the 2
mounting nuts at this time.
(5) Install and securely tighten the 2 nuts mount-
ing the steering column lower mounting bracket to
the steering column support bracket.
(6) Install the upper and lower steering column
shrouds onto the lock housing of the steering column
assembly. Install and securely tighten the 3 upper to
lower steering column shroud to lock housing attach-
ing screws (Fig. 15).
(7) Be sure both breakaway capsules are still fully
seated in the slots of the upper steering column
mounting bracket. Equally tighten both steering col-
umn mounting nuts, until upper steering column
mounting bracket is seated against support bracket.
Then tighten the 2 steering column upper mounting
bracket nuts to a torque of 17 N´m (150 in. lbs.).
(8) Tighten the steering column lower mounting
bracket nuts (2) to a torque of 17 N´m (150 in. lbs.).
(9) Assemble the steering column flex coupler to
the intermediate steering coupler (Fig. 16). Install
the steering coupler pinch bolt. Torque the pinch bolt
nut to 28 N´m (250 in. lbs.).Be sure to install
upper to lower steering coupler pinch bolt
retaining pin (Fig. 16).
(10) Install the lower instrument panel steering
column cover liner onto lower instrument panel.
Install and securely tighten the 3 liner to instrument
panel attaching screws (Fig. 7).
(11) Install lower instrument panel steering col-
umn cover (Fig. 6) on lower instrument panel. Install
and securely tighten the 4 screws (Fig. 6) attaching
steering column cover, to lower instrument panel.
CAUTION: Clock spring centering procedure MUST
be performed prior to installing steering wheel
assembly. If clock spring is not centered it may be
overextended, causing clock spring assembly to
become inoperative.
(12) Center the clock spring using the following
procedure.
²Depress the 2 plastic locking pins to disengage
clockspring locking mechanism.
²Keeping locking mechanism disengaged, rotate
the clockspring rotor in the CLOCKWISE DIREC-
TION to the end of the travel. Do not apply excessive
torque.
²From the end of travel, rotate the rotor 2 full
turns and an additional half turn in the counter-
clockwise direction. (The horn wire should end up at
the top and the squib wire at the bottom.) Engage
the clockspring locking mechanism.
Fig. 18 Steering Column Wiring Connections
Fig. 19 Steering Column Wiring Connections
PLSTEERING 19 - 41
REMOVAL AND INSTALLATION (Continued)

CAUTION: Do not install steering wheel onto shaft
of steering column assembly by driving it onto the
shaft. Pull steering wheel down onto steering col-
umn shaft using ONLY the steering wheel retaining
nut.
(13) Feed clock spring wiring leads through hole in
steering wheel (Fig. 20). Position steering wheel on
shaft of steering column assembly, making sure to fit
flats on hub of steering wheel with formations on
inside of clockspring.
(14) Install steering wheel to steering column
shaft retaining nut and tighten until steering wheel
is fully installed on shaft. The tighten steering wheel
retaining nut to a torque of 61 N´m (45 ft. lbs.).
(15) Connect the clockspring electrical leads to
components such as horn switches and speed control
switches located in the steering wheel (Fig. 11).
(16) Install air bag electrical lead from clock
spring, into connector on back of air bag module (Fig.
10).Be sure electrical connector from clock-
spring is securely latched into air bag module
connector.
CAUTION: The fasteners, screws, and bolts, origi-
nally used for the air bag components are specifi-
cally designed for the air bag system. They must
never be replaced with any substitutes. Anytime a
new fastener is needed, replace only with correct
fasteners provided in service packages or fasteners
listed in the parts book.
(17) Install air bag module into center of steering
wheel. Align air bag module mounting holes with bolt
holes in steering wheel. Installonly the 2 original
or correct replacementair bag module attachingbolts (Fig. 9). Torque the 2 air bag module attaching
bolts to 10 N´m (90 in. lbs.).
(18) Install key lock cylinder into lock housing.
Key lock cylinder is installed by positioning key cyl-
inder in the run position so retaining tab can be
depressed and the pushing key cylinder into lock hos-
ing until retaining tab locks into key lock cylinder.
(19) Reconnect ground cable to Negative post of
the battery.When reconnecting battery on a
vehicle that has had the air bag module
removed, the following procedure should be
used.
²Remove forward console or cover as necessary.
²Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
²Turn ignition key to ON position. Exit vehicle
with the DRB II. Install the latest version of the
proper diagnostic cartridge into the DRB II.
²Ensuring that their are no occupants in the
vehicle, connect negative cable to negative post of the
battery.
²Using the DRB II read and record active fault
codes. Also read and record any stored fault codes.
Refer to the Passive Restraint Diagnostic Test Man-
ual if any faults are found.
²Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
²From the passenger side of the vehicle, turn
ignition key to OFF and then ON observing instru-
ment cluster air bag lamp. It should go on for six to
eight seconds, then go out. This will indicate that the
air bag system is functioning normally.
(20)If air bag warning lamp fails to light,
blinks on and off or goes on and stays on, there
is an air bag system malfunction.Refer to the
Passive Restraint Diagnostic Test Manual to diag-
nose the system malfunction.
(21) Test the operation of the horn, lights and any
other functions that are steering column operated. If
applicable reset the radio and the clock.
(22) Road test vehicle to ensure proper operation
of the steering system and the speed control system.
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
Steering Wheel
Retaining Nut...............61N´m(45ft.lbs.)
Steering Column Assembly
Upper And Lower Mounting Bracket
Attaching Nuts...........17N´m(150 in. lbs.)
Fig. 20 Steering Wheel Installation
19 - 42 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: The transaxle output shaft is serviced as
a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
TRANSAXLE IDENTIFICATION INFORMATION
The transaxle model, assembly number, and build
date are on a metal I.D. tag that is attached to the
end cover of the transaxle (Fig. 1). This information
is also shown on a bar code label that is attached to
the front of the transaxle.
NOTE: Transaxles use various final drive gear
ratios in different vehicle applications. Therefore, it
is necessary that the correct transaxle assembly
number is used when ordering service parts.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on the case, below the
back±up lamp switch.
NOTE: There are four different versions of this
transaxle. There are no external differences
between the models. Refer to the identification tag
on the transaxle to determine which transaxle the
vehicle is equipped with.
SELECTION OF LUBRICANT
NV T350 (A-578) transaxles use MopartType M.S.
9417 Manual Transaxle Fluid.Hypoid gear lube,
engine oil, and/or automatic transmission fluid
should not be used in this transaxle.Hard shift-
ing effort, bearing, gear, and/or synchronizer failure
may occur if incorrect fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes toaid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
SEALANTS
The sealant used to seal the transaxle case halves
and input bearing is MopartGasket Maker, Loctitet
518, or equivalent. The sealant used for the bearing
end plate cover is MopartRTV.
GEAR RATIOS
CAUTION: All gears and shafts must not be inter-
changed with other transaxles; they will not func-
tion correctly.
The differential is a conventional arrangement of
gears that is supported by tapered roller bearings.
The final output gear turns the ring gear and differ-
ential assembly, thereby turning the drive axle
shafts.
All transaxles have a torque capacity of 136 lb. ft.
The gear ratios of each transaxle are shown in the
following chart. The chart also shows which transax-
les are available with the reverse±input shaft brake.
This brake allows easier shifting into reverse and
helps eliminate reverse gear clash.
ENGINE 2.0 SOHC
EUROPE
AND U.S.1.8 BUX or
2.0L
SALES
CODE
ACR1.8 RIGHT
HAND
DRIVE
ONLY
GEAR
1st 3.54 3.54 3.54
2nd 2.13 2.13 2.13
3rd 1.36 1.36 1.36
4th 1.03 1.03 1.03
5th 0.72 0.81 0.81
FINAL
DRIVE3.55 3.94 3.94
REVERSE
BRAKENO YES YES
CLUTCH
RELEASE
SYSTEMCABLE CABLE HYDRAULIC
GEARSHIFT PATTERN
The NV T350 (A-578) transaxle shift pattern is a
modified H±pattern (Fig. 2). Overdrive fifth and
reverse gears are in±line and outboard of the first
through fourth gear positions.
Fig. 1 Metal I.D. Tag
21 - 2 TRANSAXLEPL
GENERAL INFORMATION (Continued)

(12) Detach cables from cable support clip in tun-
nel above exhaust catalyst.
(13) Remove shift cable assembly from vehicle.
INSTALLATION
CAUTION: Gearshift cable bushings must not be
lubricated or the bushings will swell and split.
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CROSSOVER CABLE
ADJUSTMENT
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 12).
(3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 13). Be sure drill bit goes into transaxle
case at least one half inch.
(4) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shifter knob.
(2) Remove console assembly. Refer to Group 23,
Body for procedure.
(3) Remove shifter boot.
(4) Disconnect gearshift cables at shifter end.
(5) Remove the parking brake mechanism. Refer to
Group 5, Brakes for procedure.
(6) Remove the airbag control module. Refer to
Group 8M, Passive Restraint System for procedure.
(7) Remove the two remaining nuts at the base of
the gearshift mechanism (Fig. 14). Remove shifter.
INSTALLATION
(1) For installation, reverse removal procedure.
Fig. 12 Crossover Cable Adjustment Screw
Fig. 13 Crossover Lever Pin Procedure
Fig. 14 Gearshift Mechanism
21 - 6 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(12) Install shaft snap rings at input and output
bearings (Fig. 65).
(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. 66).
(14) Remove gear case from bench fixture.
(15) Install gear case in a holding fixture with end
cover facing down.
(16) Turn selector shaft into slot on blocker assem-
bly (Fig. 67).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers.
(18) Install reverse idler gear and shaft. Install
bolt into shaft. Tighten bolt on shaft to 26 N´m (19 ft.
lbs.) torque (Fig. 68) (Fig. 69).
Fig. 65 Snap Rings Retaining Bearings
Fig. 66 Transaxle End Cover
Fig. 67 Selector Shaft
Fig. 68 Reverse Idler Gear
Fig. 69 Reverse Idler Shaft Bolt
21 - 18 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(19) Install reverse fork bracket and reverse lock-
out. Tighten screws to 11 N´m (96 in. lbs.) torque
(Fig. 70) (Fig. 71).
(20) Install differential into gear case (Fig. 72).BEARING ADJUSTMENT PROCEDURE
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat gives a false end±play reading while gauging
for proper shims. Improperly seated bearing cups and
cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
the original drag torque after break±in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings, if one input shaft bearing is defective, replace
both input shaft bearings.
(5) Bearing cones must not be reused if removed.
(6) Turning±torque readings should be obtained
while smoothly rotating in either direction.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
NOTE: True bearing turning±torque readings can
be obtained only with the geartrain removed from
the case.
(1) Remove bearing cup and existing shim from
clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Moparttype M.S.
9417 Manual Transaxle Fluid. Install differential
assembly in transaxle gear case. Install clutch bell-
housing over gear case. Install and torque case bolts
to 29 N´m (21 ft. lbs.).
(5) Position transaxle with bellhousing facing
down on workbench with C-clamps. Position dial
indicator.
(6) Apply a medium load to differential with Tool
C-4995 and a T-handle, in the downward direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
indicator. To obtain end play readings, apply a
medium load in an upward direction while rolling
differential assembly back and forth (Fig. 73). Record
end play.
(7) The shim required for proper bearing preload is
thetotal of end play, plus (constant) preload of
Fig. 70 Reverse Fork Bracket
Fig. 71 Reverse Fork Screws
Fig. 72 Differential Assembly
PLTRANSAXLE 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)

0.18mm (0.007 in.).Never combine shims to obtain
the required preload.
(8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
Step 7. Then press the bearing cup into clutch bell-
housing.
(9) Install clutch bellhousing. Install and torque
case bolts to 26 N´m (19 ft. lbs.).
(10) Using Special Tool C-4995 and an inch-pound
torque wrench, check turning torque of the differen-
tial assembly (Fig. 74).The turning torque should
be 6 to 12 in. lbs. If the turning torque is too
high, install a 0.05mm (0.002 inch) thinner shim.
If the turning torque is too low, install a
0.05mm (0.002 inch) thicker shim.
(11) Recheck turning torque. Repeat Step 10 until
the proper turning torque is obtained.
Once proper turning torque has been established,
place gear case on the end plate. Draw a bead ofMopartGasket Maker, Loctitet518, or equivalent,
on the flat surface of the case mating flange. Install
clutch bellhousing onto gear case. Install and tighten
case bolts to 29 N´m (21 ft. lbs.).
INPUT SHAFT
DISASSEMBLY
Before disassembly of the input shaft, it is neces-
sary to check the synchronizer stop ring gap. Use a
feeler gauge to measure the gaps between the stop
rings and the speed gears. The correct gaps are listed
below:
²1stÐ1.04-1.72 mm (0.041-0.069 in).
²2ndÐ0.94-1.72 mm (0.038-0.069 in).
²3rdÐ1.37-1.93 mm (0.054-0.076 in).
²4thÐ1.41-1.97 mm (0.056-0.078 in).
²5thÐ1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
cations, it must be inspected for wear and replaced.
If the 1st or 2nd synchronizer stop ring is worn
beyond specifications, the complete output shaft
assembly must be replaced.
The input shaft incorporates the 3rd, 4th, and 5th
speed gears and synchronizers on the assembly (Fig.
75).
Fig. 73 Checking Differential Bearing End Play To
Determine Shim Thickness
Fig. 74 Checking Differential Bearing Turning
Torque
Fig. 75 Input Shaft
21 - 20 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
RING GEAR
Fig. 95 Remove Differential Bearing Cone
Fig. 96 Install Differential Bearing Cone
Fig. 97 Remove Differential Bearing Cone
Fig. 98 Install Differential Bearing Cone
Fig. 99 Remove or Install Ring Gear Bolts and Ring
Gear
PLTRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N´m (60 ft. lbs.) torque.
SPEEDOMETER DRIVE GEAR
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
REMOVAL
(1) Pry the plastic speedometer drive gear off of
the differential case using a flat blade pry tool (Fig.
100) (Fig. 101).
INSTALLATION
NOTE: A new speedometer drive gear must be
installed on differential assembly. The lip on the
speedometer drive gear must be positioned down-
ward when installing onto differential assembly.(1) Position speedometer drive gear onto differen-
tial assembly (Fig. 102).
(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
103) (Fig. 104). Do not use a hammer.
DIFFERENTIAL GEARS
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears. Refer to Speedometer
Drive Gear for service information.
Fig. 100 Pry Off Speedometer Drive Gear
Fig. 101 Speedometer Drive Gear Removed
Fig. 102 Speedometer Drive Gear
Fig. 103 Press Gear onto Diferential
21 - 26 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)