torque DODGE NEON 1999 Service Repair Manual

(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils. This repair consists of drilling out the
worn-out or damaged threads. Then tap the hole with
a Heli-Coil tap, and install a Heli-Coil insert into the
hole. This brings the hole back to its original thread
size.
Heli-Coil tools and inserts are readily available
from most automotive parts suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of Mopar ATF Plus 3ttype 7176 automatic
transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with Mopar ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopar ATF PLUS 3 (Type 7176)
automatic transmission fluid.
21 - 58 TRANSAXLEPL
SERVICE PROCEDURES (Continued)

INTERLOCK 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 Shifter/
Ignition Interlock 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 shifter/igni-
tion interlock cable (Fig. 19).
(11) Place a 1mm (0.040) shim between the larger
diameter portion of the shifter gate pin and the plas-
tic cam (Fig. 19).
(12) The spring on the interlock cable should auto-
matically 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 interlock system, perform
the Interlock System Operation Check in the Adjust-
ments section of this group.
INTERLOCK MECHANISM
REMOVAL
(1) Remove the lower column covers, ignition
switch, and shrouds. Refer to Interlock Cable
Replacement.
(2) Grasp the interlock cable and connector firmly.
Remove the interlock cable (Fig. 20).
(3) Remove the two interlock mechanism±to±steer-
ing column attaching screws (Fig. 21). Remove the
interlock housing.
INSTALLATION
(1) Position the interlock housing at steering col-
umn. Install the two interlock mechanism±to±steer-
ing column attaching screws. Torque screws to 3 N´m
(21 in. lbs.).
(2) Snap the interlock cable into the housing.
(3) Install the lower column covers, shrouds, and
ignition switch. Refer to Interlock Cable Replace-
ment.
Fig. 19 Interlock Cable Adjuster Lock
Fig. 20 Interlock Cable
Fig. 21 Interlock Mechanism
PLTRANSAXLE 21 - 63
REMOVAL AND INSTALLATION (Continued)

VEHICLE SPEED SENSOR PINION GEAR
When the sensor is removed for any reason, a
NEW O-ring must be installed on its outside diame-
ter.
REMOVAL
(1) Remove harness connector from sensor. Be sure
weather seal stays on harness connector.
(2) Remove bolt securing the sensor in the exten-
sion housing.
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor.
INSTALLATION
(1) To install, reverse the above procedure. Be sure
extension housing and sensor flange are clean prior
to installation. Always use a NEW sensor O-ring.
(2) Tighten bolt to 7 N´m (60 in. lbs.). Tighten
speedometer cable to 4 N´m (35 in. lbs.).
PARK/NEUTRAL STARTING AND BACK-UP LAMP
SWITCH
TEST
The park/neutral starting switch is the center ter-
minal of the three terminal switch. It provides
ground for the starter solenoid circuit through the
selector lever in PARK and NEUTRAL positions only.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in PARK or NEUTRAL.
(2) Check gearshift cable adjustment before replac-
ing a switch that tests bad.
REMOVAL
(1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
PARK, then to NEUTRAL position, and inspect to see
the switch operating lever fingers are centered in
switch opening.
INSTALLATION
(1) Screw the switch with a new seal into tran-
saxle case and tighten to 33 N´m (24 ft. lbs.). Retest
switch with the test lamp.
(2) Add fluid to transaxle to bring up to proper
level.
(3) The back-up lamp switch circuit is through the
two outside terminals of the three terminal switch.
(4) To test switch, remove wiring connector from
switch and test for continuity between the two out-
side pins.
(5) Continuity should exist only with transaxle in
REVERSE position.(6) No continuity should exist from either pin to
the case.
TRANSAXLE
REMOVAL
NOTE: The transaxle can be removed from the
vehicle without having to remove the engine.
The transaxle and torque converter must be
removed as an assembly; otherwise, the torque con-
verter drive plate, pump bushing, or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the plate during removal.
All transaxle components are serviced with the
transaxle out of the vehicle. The components that are
serviceable in the vehicle are:
²Axle shaft seals
²Back±up lamp switch
²End plate
²Extension housing
²Neutral safety switch
²Shift lever
²Transaxle oil pan
²Valve Body
²Vehicle speed sensor
(1) Disconnect the battery.
(2) Pull Power Distribution Center up and out of
its holding bracket. Set Power Distribution Center
aside to gain clearance.
(3) Remove battery heat shield and remove battery
from engine compartment. Remove battery tray from
engine compartment. Disconnect cruise control (if
equipped).
(4) Remove vehicle speed sensor wiring.
(5) Disconnect neutral safety switch and torque
converter control wiring at transaxle.
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushing to avoid damaging
cable isolator bushing.
(6) Disconnect gear shift cable end from transaxle
shift lever (Fig. 22). Remove bracket bolt at transaxle
(Fig. 23).
(7) Remove throttle pressure control cable from
lever. Then remove bracket bolts at the transaxle
(Fig. 24).
(8) Remove dipstick tube.
(9) Remove transaxle cooler lines and plug lines
(Fig. 25).
(10) Remove throttle pressure control cable sup-
port bracket bolts. Remove upper bellhousing bolts
and upper starter bolt (Fig. 26).
21 - 64 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: When reinstalling driveshafts, new drive-
shaft retaining clips must be used. Do not reuse old
clips. Failure to use new clips may result in disen-
gagement of inner constant±velocity joint.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.
(14) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
(15) Remove transaxle to rear lateral bending
strut from engine and transaxle (Fig. 28).
(16) Remove front engine bracket through±bolt.
Remove front engine bracket bolts (Fig. 29).
(17) Remove lower starter bolt (Fig. 30).
(18) Remove lower dust shield screw.
(19) Rotate engine clockwise to gain access to con-
verter bolts (Fig. 31). Remove torque converter bolts
(Fig. 32). Mark converter to flex plate for reassembly
ease.
(20) Support transaxle with a transmission jack.
(21) Remove left mount through±bolt (Fig. 33).
Remove left mount bolts from transaxle (Fig. 34).
(22) Remove left transaxle mount from transaxle.
(23) Remove rear engine bolt at transaxle.
(24) Carefully work transaxle and torque converter
assembly rearward off engine block dowels. Disen-
gage converter hub from end of crankshaft.Attach a
small C-clamp to edge of bellhousing. This will
hold torque converter in place during transaxle
removal.Lower transaxle and remove assembly
from under the vehicle.
INSTALLATION
(1) To install transaxle, reverse removal procedure.(2) If torque converter was removed from transaxle
be sure to align pump inner gear pilot flats with
torque converter impeller hub flats.
(3) Adjust gearshift and throttle cables.
(4) Refill transaxle with MOPARtATF PLUS 3
(Automatic Transmission Fluid) type 7176.
(5) Verify that vehicle's back-up lights and speed-
ometer are functioning properly.
Fig. 28 Bracket Removal
Fig. 29 Front Engine Bracket
Fig. 30 Starter Bolts
21 - 66 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

PUMP OIL SEAL
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly
from the transaxle case.
REMOVAL
(1) Screw seal remover Tool C-3981-B into seal
(Fig. 35), then tighten screw portion of tool to with-
draw the seal.
INSTALLATION
(1) To install a new seal, place seal in opening of
the pump housing (lip side facing inward). Using Tool
C-4193 and Handle Tool C-4171, drive new seal into
housing until tool bottoms (Fig. 36).
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
When disassembling, each part should be washed in
a suitable solvent, then dried with compressed air.
Do not wipe parts with shop towels. All mating sur-
faces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exer-
cised to avoid nicks or burrs.
Fig. 31 Rotate Engine
Fig. 32 Torque Converter Bolts
Fig. 33 Left Transaxle Mount Through±Bolt
Fig. 34 Left Mount Bolts
Fig. 35 Remove Pump Oil Seal
PLTRANSAXLE 21 - 67
REMOVAL AND INSTALLATION (Continued)

PARKING PAWL
DISASSEMBLYASSEMBLY
To install, reverse the above procedure.
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair of
output shaft. Planetary gear sets must be removed to
accurately check output shaft bearing turning torque.
STIRRUP AND RETAINING STRAP
NOTE: A stirrup and retaining strap (Fig. 143) is
attached to the output gear. The stirrup prevents
the output gear retaining nut from turning and
backing off the output shaft. The strap is used to
hold the stirrup to the output gear and prevent the
stirrup retaining bolts from backing out.
REMOVAL
(1) Using a punch, bend tabs on strap flat against
output gear (Fig. 144).
Fig. 140 Parking Sprag Rod Support
Fig. 141 Support and Bolts
Fig. 142 Parking Pawl, Return Spring, and Pivot Shaft
Fig. 143 Stirrup and Retaining Strap Assembly
Fig. 144 Bend Strap Tabs Flat
PLTRANSAXLE 21 - 89
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearing turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 161 Install Output Shaft Gear Bearing Cup
Fig. 162 Install Rear Planetary Annulus Gear
Bearing Cup
Fig. 163 Install Output Shaft Assembly
Fig. 164 Output Shaft and (Select) Shims in Position
Fig. 165 Start Output Shaft Gear onto Output Shaft
PLTRANSAXLE 21 - 93
DISASSEMBLY AND ASSEMBLY (Continued)

STIRRUP AND RETAINING STRAP
INSTALLATION
Once bearing turning torque and shim selection
has been adjusted, install stirrup and strap assembly
onto output gear.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.
(1) Position the stirrup on the output gear.
(2) Position strap.
(3) Install retaining bolts into output gear. Finger-
±tighten bolts.
(4) Turn stirrup clockwise against the flats of the
output gear retaining nut (Fig. 170).
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.)
(Fig. 171).
(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
Fig. 166 Holding Output Shaft Gear
Fig. 167 Tighten Output Shaft Retaining Nut to 271
N´m (200 ft. lbs.)
Fig. 168 Checking Output Shaft End Play
Fig. 169 Checking Bearing Turning Torque
Fig. 170 Turn Stirrup Clockwise Against Flats Of
Retaining Nut
21 - 94 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for dif-
ferential repair and bearing turning torque checking.
NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential cover.
Fig. 171 Tighten Strap Retaining Nuts
Fig. 172 Remove Extension Seal
Fig. 173 Install New Seal into Extension
Fig. 174 Differential Cover Bolts
Fig. 175 Remove or Install Differential Cover
Fig. 176 Remove Bearing Retainer Axle Seal
PLTRANSAXLE 21 - 95
DISASSEMBLY AND ASSEMBLY (Continued)

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 shifter/igni-
tion interlock cable (Fig. 198).
(11) The spring on the interlock cable should auto-
matically compensate for the slack in the adjuster.
(12) Then snap down the interlock adjuster lock
onto cable.
(13) After adjusting the interlock system, perform
the interlock system operation check. See Interlock
System Operation Check in this section.
BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The kickdown band adjusting screw is located on
left side (top front) of the transaxle case.
(1) Loosen locknut and back±off nut approximately
five turns. Test adjusting screw for free turning in
the transaxle case.
(2) Using wrench, tighten adjusting screw to 8
N´m (72 in. lbs.).
(3) Back±off adjusting screw the number of turns
listed in Specifications. Hold adjusting screw in this
position and tighten locknut to 47 N´m (35ft. lbs.)
LOW/REVERSE BAND (REAR)
To adjust low/reverse band, proceed as follows:
(1) Loosen and back off locknut approximately five
turns.
(2) Using an inch-pound torque wrench, tighten
adjusting screw to 5 N´m (41 in. lbs.) true torque.(3) Back±off adjusting screw the number of turns
listed under Specifications. A chart is located at the
rear of this section.
(4) Tighten locknut to 14 N´m (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect and
correct throttle pressure adjustment before adjusting
the line pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to
obtain specified line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
BEARING ADJUSTMENT PROCEDURES
(1) Take 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 bearing seat will give a false end play
reading, while gauging for proper shims. Improperly
seated bearing cup and cones are subject to low-mile-
age failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress.
(3) If distress is seen on either the cup or bearing
rollers, both cup and cone must be replaced.
NOTE: Bearing end play and drag torque specifica-
tions must be maintained to avoid premature bear-
ing failures.
Fig. 198 Interlock Cable Adjuster Lock
PLTRANSAXLE 21 - 101
ADJUSTMENTS (Continued)