lock DODGE NEON 1999 Service Repair Manual

(13) Remove steering wheel assembly from steer-
ing column shaft using Puller, Special Tool C-3428-B
or equivalent.
(14) Remove key lock cylinder from steering col-
umn. Key lock cylinder is removed from steering col-
umn using the following procedure. Place the key
lock cylinder in the Run position. Then through the
hole in lower shroud, (Fig. 14) depress lock cylinder
retaining tab and remove key lock cylinder.
(15) Remove the 3 screws attaching the upper and
lower shroud to the steering column (Fig. 15). First
remove lower shroud from steering column, then
release tilt lever and tilt steering column to its low-
est point. Then remove upper shroud from steering
column.
(16) Remove retaining pin from pinch bolt in steer-
ing column upper coupling (Fig. 16).
(17) Loosen the steering column upper coupling
pinch bolt retaining nut and remove pinch bolt (Fig.
16) from steering coupling.(Pinch bolt nut iscaged to coupler and is not removable.)Then
separate steering column shaft coupling from lower
steering coupling.
(18) Remove the 2 nuts attaching the lower
mounting bracket of the steering column to the steer-
ing column mounting bracket.
(19) Remove the 2 nuts mounting the steering col-
umn upper bracket to the steering column support
bracket (Fig. 17).
(20) Lower steering column in the steering column
access opening of the lower instrument panel.
(21) Remove routing clip (Fig. 18) holding wiring
harness to jacket of steering column. Then remove
wiring harness connectors from the multi- function
switch and the windshield wiper switch (Fig. 18).
(22) Remove the vehicle wiring harness connec-
tors from the ignition switch and clock spring (Fig.
19).
Fig. 14 Key Lock Cylinder Access Hole In Steering
Column Shrouds
Fig. 15 Upper And Lower Steering Column Shrouds
Fig. 16 Upper To Lower Steering Column Coupler
Disassembly
Fig. 17 Steering Column Upper Support Bracket
Attaching Nuts
19 - 40 STEERINGPL
REMOVAL AND INSTALLATION (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)

TRANSAXLE
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE............. 40 NVT350 (A-578) MANUAL TRANSAXLE....... 1
NV T350 (A-578) MANUAL TRANSAXLE
INDEX
page page
GENERAL INFORMATION
GEAR RATIOS........................... 2
GEARSHIFT PATTERN..................... 2
NV T350 MANUAL TRANSAXLE.............. 1
SEALANTS.............................. 2
SELECTION OF LUBRICANT................ 2
SPECIAL ADDITIVES...................... 2
TRANSAXLE IDENTIFICATION INFORMATION . . . 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
SHIFT LEVERS.......................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS...................... 3
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 3
LOW LUBRICANT LEVEL................... 3
NOISY OPERATION....................... 3
SLIPS OUT OF GEAR..................... 3
SERVICE PROCEDURES
FLUID DRAIN AND FILL.................... 3
REMOVAL AND INSTALLATION
AXLE SEALS............................ 8
BACK-UP LAMP SWITCH................... 7
CROSSOVER LEVER...................... 7
GEARSHIFT BOOT....................... 4
GEARSHIFT CABLES...................... 4GEARSHIFT KNOB....................... 4
GEARSHIFT MECHANISM REPLACEMENT..... 6
SELECTOR LEVER....................... 8
SHIFT SHAFT SEALS...................... 8
TRANSAXLE............................ 8
VEHICLE SPEED SENSOR DRIVE GEAR...... 7
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 24
INPUT SHAFT.......................... 20
OUTPUT SHAFT........................ 24
SHIFT RAILS OVERHAUL................. 29
SYNCHRONIZER........................ 29
TRANSAXLE CASE OVERHAUL............. 30
TRANSAXLE........................... 10
CLEANING AND INSPECTION
SYNCHRONIZER........................ 35
TRANSAXLE........................... 35
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 35
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT......................... 36
GEARSHIFT CROSSOVER CABLE........... 35
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS.......... 37
SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE....... 37
GENERAL INFORMATION
NV T350 MANUAL TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This five speed is a constant-mesh manual tran-
saxle. All gear ranges, except reverse, are synchro-
nized. The reverse gear utilizes a brake and blockingring for shifting ease. The reverse idler gear is sup-
ported on a sliding spindle idler shaft. The transaxle
case is aluminum with a steel end±plate bearing
cover. It is housed in a die-cast aluminum case fea-
turing a two±piece, middle split design.
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
PLTRANSAXLE 21 - 1

(22) Rotate engine crankshaft clockwise to expose
driveplate±to±modular clutch bolts.
NOTE: Before removal of bolts, mark the driveplate
and clutch pressure plate for ease of assembly
alignment.
(23) Remove four driveplate±to±modular clutch
bolts to separate driveplate from clutch assembly.
(24) Push modular clutch assembly into the tran-
saxle bellhousing for easier transaxle removal.
(25) Remove frame rail to left transaxle mount
through-bolt (Fig. 26).
(26) Remove left transaxle mount from transaxle.
Then push mount up to gain clearance for transaxle
removal.(27) Remove transaxle from vehicle.
(28) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
(1) To install transaxle, reverse removal procedure.
(2) After installing transaxle, fill transaxle to bot-
tom of fill plug hole (vehicle level on hoist). Fill tran-
saxle with Moparttype M.S. 9417 Manual Transaxle
Fluid before lowering vehicle to floor.
(3) Verify that vehicle's back-up lights and speed-
ometer are functioning properly. Crossover cable
adjustment procedure is required after installing
transaxle in car to ensure proper shifter adjustment.
Road test vehicle for proper transaxle function.
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
CAUTION: The transaxle output shaft is serviced
as a unit. No disassembly and reassembly is possi-
ble. Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench.
(2) Remove shift levers. Remove transaxle case
half bolts (Fig. 27).
(3) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 28). Separate
the case halves (Fig. 29).
(4) Remove bellhousing half from gear case half
(Fig. 30).
(5) Remove output shaft roller bearing from output
shaft.
Fig. 24 Starter Bolts
Fig. 25 Bracket Removal
Fig. 26 Left Transaxle Mount Through-Bolt
21 - 10 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(8) Remove two screws retaining reverse fork
bracket (Fig. 34). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 35).(9) Using snap±ring pliers, remove selector shaft
spacer (Fig. 36).
(10) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 37).
Fig. 33 Reverse Idler Gear Removal
Fig. 34 Screws Retaining Reverse Fork Bracket
Fig. 35 Remove Reverse Fork Bracket
Fig. 36 Remove Selector Shaft Spacer
Fig. 37 Selector Shaft
21 - 12 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(18)TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim,
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 46) (Fig. 47) (Fig. 48)(Fig. 49) (Fig. 50).TRANSAXLE W/O REVERSE
BRAKE:Remove plastic spacer from the input shaft
assembly.
Fig. 43 Pressing Gears Out of Case
Fig. 44 Transaxle Case Removal
Fig. 45 Oil Feed Trough
Fig. 46 Reverse Brake Shim
Fig. 47 Reverse Brake Friction Cone
Fig. 48 Reverse Brake Blocking Ring
21 - 14 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(19) Remove the shift blocker assembly from the
bench fixture (Fig. 51).
(20) Remove the 1-2 shift fork from the output
shaft (Fig. 52).(21) Remove input and output shaft assemblies
from bench fixture (Fig. 53).
CAUTION: The output shaft assembly is serviced
as an assembly. Do not try to repair any component
on the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the complete output
shaft assembly.
ASSEMBLY
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end plate cover is
MopartRTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 54).
(2) Install shift rails and forks into bench fixture
(Fig. 55).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 56).
Fig. 49 Reverse Brake Needle Bearing
Fig. 50 Reverse Brake Race
Fig. 51 Shift Blocker Removal
Fig. 52 1±2 Shift Fork Removal
Fig. 53 Gear Train Removal
PLTRANSAXLE 21 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Install reverse brake race onto input shaft (Fig.
57).
(5) Install reverse brake needle bearing (Fig. 58).
(6) Install reverse brake blocking ring (Fig. 59).
Fig. 54 Bench Fixture
Fig. 55 Shift Rail Installation
Fig. 56 Shift Blocker Installation
Fig. 57 Reverse Brake Race Installation
Fig. 58 Reverse Brake Needle Bearing
Fig. 59 Reverse Brake Blocking Ring Installation
21 - 16 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (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)