torque DODGE NEON 1999 Service Repair Manual

REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro keys and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 136).(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. 137). 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.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
Fig. 136 Crossover Cable Adjustment Screw
Fig. 137 Crossover Lever Pin Procedure
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat will give 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
their 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. 138).
Record end play.
(7) The shim required for proper bearing preload is
thetotal of end play, plus (constant) preload of
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 inStep 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. 139).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.
Fig. 138 Checking Differential Bearing End Play to
Determine Shim Thickness
Fig. 139 Checking Differential Bearing Turning
Torque
21 - 36 TRANSAXLEPL
ADJUSTMENTS (Continued)

SPECIFICATIONS
NV T350 (A-578)
DESCRIPTION TORQUE
Back-up Lamp Switch..........24N´m(18ft.lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug.................30N´m(267 in. lbs.)
Differential Ring Gear Bolts.....81N´m(60ft.lbs.)
Dust Shield to Transaxle......12N´m(105 in. lbs.)
End Plate Cover Bolts.........29N´m(21ft.lbs.)
Front Engine Mount to Trans . . .108 N´m (80 ft. lbs.)
Front Mount Through Bolt......61N´m(45ft.lbs.)
Front Mount to Engine Bolt.....54N´m(40ft.lbs.)
Lateral Bending
Strut to Engine.............54N´m(40ft.lbs.)
Lateral Bending Strut to Trans. . .54 N´m (40 ft. lbs.)
Left Mount Through Bolt......108 N´m (80 ft. lbs.)
Left Mount to Transaxle........54N´m(40ft.lbs.)
Output Bearing Race Ret. Strap .11 N´m (96 in. lbs.)
Power Hop Damper Bkt. to
Trans.....................54N´m(40ft.lbs.)
Power Hop Damper to
Frame Bkt.................54N´m(40ft.lbs.)
Power Hop Damper to
Trans. Bkt.................54N´m(40ft.lbs.)
Reverse Fork Bracket..........11N´m(96in.lbs.)
Reverse Idler Shaft Bolt........26N´m(19ft.lbs.)
Shift Cable Bracket to
Transaxle................28N´m(250 in. lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Transaxle to Engine Bolt.......95N´m(70ft.lbs.)
Trans. to Eng. Intake Bkt. Bolts . .95 N´m (70 ft. lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vertical Bending Strut to
Engine..................108 N´m (80 ft. lbs.)
Vertical Bending Strut to Trans. .108 N´m (80 ft. lbs.)
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
SPECIAL TOOLS
SPECIAL TOOLS±NV T350 (A-578) MANUAL
TRANSAXLE
NV T350 (A-578) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
NV T350 1.9-2.2 Liters 2.0-2.3 Quarts
Adapter Blocks C-293±45
Puller Press C-293±PA
Dial Indicator C-3339
Sleeve C-3717
PLTRANSAXLE 21 - 37

Slide Hammer C-3752
Universal Handle C-4171
Bearing Installer C-4628
Seal Remover C-4680
Seal Installer C-4992
Torque Tool C-4995
Adapter C-4996
Installer L-4410
21 - 38 TRANSAXLEPL
SPECIAL TOOLS (Continued)

31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
FLUID LEVEL AND CONDITION............. 41
GENERAL INFORMATION................. 40
SELECTION OF LUBRICANT............... 41
SPECIAL ADDITIVES..................... 41
DESCRIPTION AND OPERATION
AUTOMATIC TRANSMISSION SHIFTER/
IGNITION INTERLOCK.................. 42
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR....................... 42
FLOW CONTROL VALVES................. 42
GEARSHIFT AND PARKING LOCK CONTROLS . 42
GOVERNOR............................ 43
HYDRAULIC CONTROL SYSTEM............ 42
PRESSURE REGULATING VALVES.......... 42
PRESSURE SUPPLY SYSTEM.............. 42
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR.................. 43
TORQUE CONVERTER CLUTCH............ 42
DIAGNOSIS AND TESTING
CLUTCH AND SERVO AIR PRESSURE TESTS . 54
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA............ 55
HYDRAULIC PRESSURE TESTS............ 52
INTERLOCK SYSTEM OPERATION CHECK.... 55
ROAD TEST............................ 52
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS.............................. 43
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR.............. 58
FLUID AND FILTER CHANGE............... 56
FLUID DRAIN AND REFILL................. 57
FLUSHING COOLERS AND TUBES.......... 58
OIL PUMP VOLUME CHECK............... 58
REMOVAL AND INSTALLATION
GEARSHIFT CABLE...................... 59
GEARSHIFT MECHANISM................. 60
INTERLOCK MECHANISM................. 63
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH........................ 64
PUMP OIL SEAL......................... 67
SHIFTER IGNITION INTERLOCK CABLE...... 61THROTTLE PRESSURE CABLE............. 60
TRANSAXLE........................... 64
VEHICLE SPEED SENSOR PINION GEAR..... 64
DISASSEMBLY AND ASSEMBLY
ACCUMULATOR-RECONDITION............ 83
DIFFERENTIAL REPAIR................... 95
FRONT CLUTCH-RECONDITION............ 78
FRONT PLANETARY AND ANNULUS GEAR-
RECONDITION........................ 81
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................ 83
LOW/REVERSE (REAR)
SERVO-RECONDITION.................. 82
OIL PUMP-RECONDITION................. 78
OUTPUT SHAFT REPAIR.................. 89
PARKING PAWL......................... 89
REAR CLUTCH-RECONDITION............. 79
TRANSAXLE........................... 67
TRANSFER SHAFT REPAIR................ 83
VALVE BODY RECONDITION............... 74
CLEANING AND INSPECTION
VALVE BODY........................... 99
ADJUSTMENTS
BAND ADJUSTMENT.................... 101
BEARING ADJUSTMENT PROCEDURES..... 101
DIFFERENTIAL BEARING................. 102
GEARSHIFT CABLE...................... 99
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS....................... 101
OUTPUT SHAFT BEARING................ 102
SHIFTER/IGNITION INTERLOCK SYSTEM.... 100
THROTTLE PRESSURE CABLE ADJUSTMENT
PROCEDURE........................ 100
TRANSFER SHAFT BEARING............. 103
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . 105
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE............ 113
31TH TRANSAXLE TORQUE
SPECIFICATIONS..................... 113
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE............ 114
GENERAL INFORMATION
GENERAL INFORMATION
NOTE: Safety goggles should be worn at all times
when working on these transaxles.This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
21 - 40 TRANSAXLEPL

NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
fluid through a remote cooler. There are two types of
coolers used. An oil-to-water type cooler located in
the radiator side tank and/or an oil-to-air heat
exchanger. The torque converter assembly is a sealed
unit that cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.
Engine torque is transmitted to the torque con-
verter and then through the input shaft to multiple-
disc clutches in the transaxle. The power flow
depends on the application of the clutches and bands.
Refer to Elements in Use Chart in Diagnosis and
Tests section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The driving shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor in the
transaxle final drive (axle) ratio. The shaft also car-
ries the governor and parking sprag. An integral heli-cal gear on the transfer shaft drives the differential
ring gear. The final drive gearing is completed with
one of two gear ratios; 2.98 or 3.19 depending on
model and application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fills in both the P (Park) and
N (Neutral) positions. Place the selector lever in P
(Park) to be sure that the fluid level check is accu-
rate.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. This will ensure complete oil
level stabilization between differential and
transmission.The fluid should be at normal operat-
ing temperature (approximately 82É C. or 180É F.).
The fluid level is correct if it is in the HOT region
(cross-hatched area) on the dipstick.
Low fluid level can cause a variety of conditions,
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy therefore, pressures will be
low and will build up slowly.
Improper filling also can raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
that occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming also can result in fluid escaping from the
transaxle dipstick, where it may be mistaken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
or is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
these transmissions. Mopar ATF PLUS 3 (Automatic
Transmission Fluid- type 7176) should be used to aid
in ensuring optimum transmission performance. It is
important that the transmission fluid be maintained
at the prescribed level using the recommended fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transmission, other than
that fluid listed above. An exception to this policy is
PLTRANSAXLE 21 - 41
GENERAL INFORMATION (Continued)

the use of special dyes to aid in detecting fluid leaks.
The use of transmission sealers should be avoided,
since they may adversely affect seals.
DESCRIPTION AND OPERATION
TORQUE CONVERTER CLUTCH
A torque converter clutch is standard on all vehi-
cles. The torque converter clutch is activated only in
direct drive and is controlled by the engine electron-
ics. A solenoid on the valve body, is powered by the
powertrain control module to activate the torque con-
verter clutch.
HYDRAULIC CONTROL SYSTEM
The hydraulic control system makes the transaxle
fully automatic, and has four important functions to
perform. The components of any automatic control
system may be grouped into the following basic
groups:
²Pressure supply system
²Pressure regulating valves
²Flow control valves
²Clutches
²Band servos
Taking each of these basic groups or systems in
turn, the control system may be described as follows:
PRESSURE SUPPLY SYSTEM
The pressure supply system consists of an oil pump
driven by the engine through the torque converter.
The single pump furnishes pressure for all hydraulic
and lubrication requirements.Oil pump housing
assemblies are available with preselected pump
gears.
PRESSURE REGULATING VALVES
The pressure regulating valve controls line pres-
sure dependent on throttle opening. The governor
valve transmits regulated pressure to the valve body
(in conjunction with vehicle speed) to control upshift
and downshift.
The throttle valve transmits regulated pressure to
the transaxle (dependent on throttle position) to con-
trol upshift and downshift.
FLOW CONTROL VALVES
The manual valve provides the different transaxle
drive ranges selected by the vehicle operator.
The 1-2 shift valve automatically shifts the tran-
saxle from first to second or from second to first,
depending on the vehicle operation.
The 2-3 shift valve automatically shifts the tran-
saxle from second to third or from third to second
depending on the vehicle operation.The kickdown valve makes possible a forced down-
shift from third to second, second to first, or third to
first (depending on vehicle speed). This can be done
by depressing the accelerator pedal past the detent
feel near wide open throttle.
The shuttle valve has two separate functions and
performs each independently of the other. The first is
providing fast release of the kickdown band, and
smooth front clutch engagement when a lift-foot
upshift from second to third is made. The second
function is to regulate the application of the kick-
down servo and band when making third±to±second
kickdown.
The bypass valve provides for smooth application
of the kickdown band on 1-2 upshifts.
The torque converter clutch solenoid allows for the
electronic control of the torque converter clutch. It
also disengages the torque converter at closed throt-
tle. This is done during engine warm-up and part-
throttle acceleration.
The switch valve directs oil to apply the torque
converter clutch in one position. The switch valve
releases the torque converter clutch in the other posi-
tion.
CLUTCHES, BAND SERVOS, AND ACCUMULATOR
The front and rear clutch pistons, and both servo
pistons, are moved hydraulically to engage the
clutches and apply the bands. The pistons are
released by spring tension when hydraulic pressure
is released. On the 2-3 upshift, the kickdown servo
piston is released by spring tension and hydraulic
pressure.
The accumulator controls the hydraulic pressure
on the apply±side of the kickdown servo during the
1-2 upshift; thereby cushioning the kickdown band
application at any throttle position.
AUTOMATIC TRANSMISSION SHIFTER/IGNITION
INTERLOCK
The Shifter/Ignition Interlock, is a mechanical
cable operated system (Fig. 1). It interconnects the
automatic transmission floor±mounted shifter to the
steering column ignition switch. The interlock system
locks the floor±mounted shift lever into the PARK
position whenever the ignition switch is in the LOCK
or ACCESSORY position. When the key is in the
OFF or RUN position, the shifter is unlocked and
will move into any position. Also the interlock system
prevents the ignition switch from being turned to
LOCK or ACCESSORY position, unless shifter is in
the PARK position.
GEARSHIFT AND PARKING LOCK CONTROLS
The transaxle is controlled by alever typegear-
shift incorporated within the console. The control has
21 - 42 TRANSAXLEPL
GENERAL INFORMATION (Continued)

six selector lever positions: P (Park), R (Reverse), N
(Neutral), and D (Drive), 2 (Second), and 1 (First).
The parking lock is applied by moving the selector
lever past a gate to the (P) position.Do not apply
the parking lock until the vehicle has stopped;
otherwise, a severe banging noise will occur.
TORQUE CONVERTER CLUTCH SOLENOID WIRING
CONNECTOR
If the solenoid wiring connector is unplugged, the
torque converter will not engage (Fig. 2).
GOVERNOR
The governor can be serviced by removing the
transaxle oil pan and valve body assembly. The gov-
ernor can be unbolted from the governor support and
removed from the transaxle for reconditioning or
replacement.
When cleaning or assembling the governor, be sure
the governor valves move freely in the bores of the
governor body.
DIAGNOSIS AND TESTING
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS
Automatic transaxle malfunctions may be caused
by four general conditions:
(1) Poor engine performance
(2) Improper adjustments
(3) Hydraulic malfunctions
(4) Mechanical malfunctions
Diagnosis of these problems should always begin
by checking the easily accessible variables; fluid level
and condition, gearshift cable adjustment, and throt-
tle pressure cable adjustment. Then perform a road
test to determine if the problem has been corrected
or that more diagnosis is necessary. If the problem
exists after the preliminary tests and corrections are
completed, hydraulic pressure tests should be per-
formed
31TH HYDRAULIC TROUBLE CODE CHARTS
The following charts should be used to help diag-
nose hydraulic or mechanical faults in the transaxle.
Fig. 1 Shifter Ignition Interlock System Components
Fig. 2 Torque Converter Clutch Solenoid Wiring
Connector
PLTRANSAXLE 21 - 43
DESCRIPTION AND OPERATION (Continued)

LOW AND REVERSE SERVO (REAR)
Direct air pressure into LOW/REVERSE SERVO
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
ton should release the band.
If clutches and servos operate properly, no upshift
indicates that a malfunction exists in the valve body.
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA
(1) Check for source of leakage.
(2) Since fluid leakage near the torque converter
area may be from an engine oil leak, the area should
be checked closely. Factory fill fluid is dyed red and,
therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
vent in the dipstick. If the fluid level is high, adjust
to proper level.
(6) After performing this operation, inspect for
leakage. If a leak persists, perform the followingoperation on the vehicle. This will determine if the
torque converter or transaxle is leaking.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter (peripheral) weld
²Torque converter hub weld
²Torque converter impeller shell cracked adjacent
to hub
²At drive lug welds
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
INTERLOCK SYSTEM OPERATION CHECK
(1) Place shifter in PARK, the ignition switch
should rotate freely from OFF to LOCK position.
When the shifter is moved to the DRIVE position,
the ignition switch should not rotate from OFF to
LOCK.
(2) Moving shifter out of PARK should be possible
only when ignition switch is in the OFF or the RUN
position. Movement of the shifter from the PARK
Fig. 5 Air Pressure Tests
PLTRANSAXLE 21 - 55
DIAGNOSIS AND TESTING (Continued)

position should not be possible when the ignition
switch is in the LOCK or the ACCESSORY position.
(3) If the interlock system, operates in any way
other than as described above, repair of the interlock
system is required. See Adjustment and Repair pro-
cedures in this section for the required procedures.
SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only fluids
labeled MOPARtATF PLUS 3 (Automatic Transmis-
sion fluid) Type 7176 should be used.
If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehicle attains 30,000 miles on its odome-
ter it is recommended that the transaxle oil be
changed. To change the oil, use the procedure that
follows:
It is recommended that a transaxle fluid exchanger
(ATF 2000+ or equivalent) be used to replace the
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculayor equiv-
alent) to draw the fluid out of the dipstick tube. If a
fluid suction pump is not available remove the oil
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle till it reaches full operating temperature.
(2) Verify that the fill tank on the transaxle fluid
exchanger (ATF 2000+ or equivalent) is clean and
dry.
(3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
(4) Hookup the vehicle to the machine following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopar ATF Plus 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N²m (18 in. lbs.).DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
21 - 56 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)