lock DODGE NEON 1999 Service Repair Manual

(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi.as lever is moved counter-
clockwise.
(6) Low/reverse pressure should read the same as
line pressure, within 3 psi.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and rear servo hydraulic
circuits.
TEST TWO (SELECTOR IN 2)
(1) Attach one gauge to line pressure port, and tee
another gauge into lower cooler line fitting. This will
allow lubrication pressure readings to be taken..
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle one detent for-
ward from full rearward position. This is selector 2
position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Lubrication pressure should be 10 to 25 psi
with lever clockwise and 10 to 35 psi with lever at
full counterclockwise.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and lubrication hydraulic
circuits.
TEST THREE (SELECTOR IN D)
(1) Attach gauges to line and kickdown release
ports.
(2) Operate engine at 1600 rpm for test.
Fig. 3 Test Port Locations
Fig. 4 Governor Pressure Tap
PLTRANSAXLE 21 - 53
DIAGNOSIS AND TESTING (Continued)

(3) Move selector lever on transaxle two detents
forward from full rearward position. This is selector
D position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise to the full
counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Kickdown release is pressurized only in direct
drive and should be same as line pressure within 3
psi, up to kickdown point.
(7) This tests pump output, pressure regulation,
and condition of rear clutch, front clutch, and
hydraulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to low-reverse port.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle four detents
forward from full rearward position. This is selector
R position.
(4) Low/reverse pressure should read 180 to 220
psi with throttle lever clockwise. Pressure should
gradually increase to 260 to 300 psi. as lever is
moved counterclockwise.
(5) This tests pump output, pressure regulation,
and condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to D position
to check that low/reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to
case porosity, which can cause reverse band burn out.
TEST RESULT INDICATIONS
(1) If proper line pressure, minimum to maximum,
is found in any one test, the pump and pressure reg-
ulator are working properly.
(2) Low pressure in D, 1, and 2 but correct pres-
sure in R, indicates rear clutch circuit leakage.
(3) Low pressure in D and R, but correct pressure
in 1 indicates front clutch circuit leakage.
(4) Low pressure in R and 1, but correct pressure
in 2 indicates rear servo circuit leakage.
(5) Low line pressure in all positions indicates a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GOVERNOR PRESSURE
Test only if transaxle shifts at wrong vehicle
speeds when throttle cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off point. It is located at lower right
side of case, below differential cover.
(2) Operate transaxle in third gear to read pres-
sures. The governor pressure should respondsmoothly to changes in mph and should return to 0
to 3 psi when vehicle is stopped. High pressure
(above 3 psi) at standstill will prevent the transaxle
from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure.
Incorrect throttle pressure should be suspected if
part throttle upshift speeds are either delayed or
occur too early in relation to vehicle speed. Engine
runaway on shifts can also be an indicator of low
throttle pressure setting, or misadjusted throttle
cable.
In no case should throttle pressure be adjusted
until the transaxle throttle cable adjustment has
been verified to be correct.
CLUTCH AND SERVO AIR PRESSURE TESTS
A no±drive condition might exist even with correct
fluid pressure, because of inoperative clutches or
bands. The inoperative units, clutches, bands, and
servos can be located through a series of tests. This
is done by substituting air pressure for fluid pressure
(Fig. 5).
The front and rear clutches, kickdown servo, and
low/reverse servo can be tested by applying air pres-
sure to their respective passages. To make air pres-
sure tests, proceed as follows:
NOTE: Compressed air supply must be free of all
dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. Refer to Valve
Body for removal procedure.
FRONT CLUTCH
Apply air pressure to front clutch apply passage
and listen for a dull thud, which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
REAR CLUTCH
Apply air pressure to rear clutch apply passage
and listen for a dull thud, which indicates that rear
clutch is operating. Also, inspect for excessive oil
leaks. If a dull thud cannot be heard in the clutches,
place finger tips on clutch housing and again apply
air pressure. Movement of piston can be felt as the
clutch is applied.
KICKDOWN SERVO (FRONT)
Direct air pressure into KICKDOWN SERVO ON
passage. Operation of servo is indicated by a tighten-
ing of front band. Spring tension on servo piston
should release the band.
21 - 54 TRANSAXLEPL
DIAGNOSIS AND TESTING (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)

(18) Carefully remove the cable from the under-
body by unfolding the cable retainer clip as you go
along.
INSTALLATION
(1) To install gearshift cable, reverse removal pro-
cedure.
(2) Adjust gearshift cable using the adjustment
procedure in this Group.
GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable and isolate.
(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) Using a flat±blade pry tool, remove the shifter
cable end from the gearshift pin (Fig. 10).
(6) Pry the two tabs on the cable conduit end away
from the gearshift mechanism and pull up on the
cable. Remove the gearshift cable from the gearshift
mechanism.
(7) Pry up the adjuster lock on the shifter/ignition
interlock cable. Unsnap the shifter/ignition interlock
cable end fitting from the groove in the gearshift
mechanism. Remove the cable core end from the
plastic cam of the shifter mechanism (Fig. 11).
(8) Remove the nuts at the base of the gearshift
mechanism (Fig. 12). Remove the shifter mechanism.
INSTALLATION
(1) For installation, reverse removal steps. Refer to
Cable Adjustment for proper cable adjustment proce-
dure.
THROTTLE PRESSURE CABLE
REMOVAL
(1) Unsnap the throttle pressure cable end at the
throttle control lever at transaxle (Fig. 13).
(2) Squeeze the retaining tabs inward at the
mounting bracket (Fig. 14). Remove the cable from
the bracket.
(3) Unsnap the cable end from the throttle linkage
cam. Squeeze the tabs inward at the bracket (Fig.
15). Remove the cable from the vehicle.
INSTALLATION
(1) To install cable, reverse removal procedure.
Refer to cable adjustment procedure for proper cable
adjustment.
THROTTLE PRESSURE CABLE ADJUSTMENT
PROCEDURE
The throttle pressure cable adjustment is very
important to proper transaxle operation. This adjust-
ment positions a valve that controls shift speed, shift
Fig. 10 Gearshift Cable
Fig. 11 Shifter Ignition Interlock Cable
Fig. 12 Gearshift Mechanism
21 - 60 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

quality, and part throttle downshift sensitivity. If the
setting is too long, early shifts and slippage between
shifts may occur. If the setting is too short, shiftsmay be delayed and part throttle downshifts may be
very sensitive.
(1) Perform transaxle throttle pressure cable
adjustment while engine is at normal operating tem-
perature.
(2) Release cross-lock on the cable assembly (pull
cross-lock upward) See (Fig. 14).
(3) To insure proper adjustment, the cable must be
free to slide all the way toward the engine, against
its stop, after the cross-lock is released.
(4) Move transaxle throttle control lever fully
clockwise, against its internal stop, and press cross-
lock downward into locked position.
The adjustment is complete and transaxle throttle
cable backlash was automatically removed.
Test cable freedom of operation by moving the
transaxle throttle lever forward (counterclockwise).
Then slowly release it to confirm it will return fully
rearward (clockwise).
No lubrication is required for any component of the
throttle cable system.
SHIFTER IGNITION INTERLOCK CABLE
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 shifter/ignition
interlock cable. Unsnap the shifter/ignition interlock
cable end fitting from the groove in the gearshift
mechanism (Fig. 16).
(6) Remove the cable core end from the plastic cam
of the shifter mechanism.
Fig. 13 Throttle Pressure Cable And Lever
Fig. 14 Throttle Pressure Cable Bracket
Fig. 15 Cable End At Throttle Linkage
Fig. 16 Shifter Ignition Interlock Cable
PLTRANSAXLE 21 - 61
REMOVAL AND INSTALLATION (Continued)

(7) Pull cable up and out of the gearshift mecha-
nism.
(8) Remove the three screws along the bottom of
the lower steering column cover and screw on the left
outward face of cover.
(9) Grasp the cover and pull rearward until the
clips disengage.
(10) Remove two screws at the upper area of the
column liner and lower left corner.
(11) Remove steering column cover and steering
column cover liner.
(12) Lift up the top cover and cluster bezel until
the clips disengage and separate to provide clear-
ance.
(13) Insert a screwdriver into access hole in the
lower shroud. Depress the cylinder button while
rotating the cylinder with the key inserted between
the ON and START positions. This will disengage the
cylinder from the column.
(14) Pull out the key cylinder.
(15) Remove the three lower±to±upper shroud
attaching screws through the bottom of the lower
shroud.
(16) Separate the upper and lower shrouds.
(17) Grasp the interlock cable clip and connector.
Remove the cable from the interlock housing (Fig.
17).
(18) Unclip the cable from the retaining clip
located within the wiring harness.
(19) Remove interlock cable from under center con-
sole mounting bracket and out front of dash panel.
INSTALLATION
CAUTION: When installing interlock cable assem-
bly, care must be taken not to bend exposed cable
wire and slug at shifter end of cable.
(1) Route interlock cable into lower dash panel.(2) Install the ignition switch into housing. Turn
the ignition switch to the RUN position.
(3) Install the interlock cable into the interlock
housing at the steering column (Fig. 18). Verify the
cable snaps into the housing.
(4) Install interlock cable into routing clip located
within the wiring harness.
(5) Route interlock cable to the console.
(6) Install the cable core end to the plastic cam of
the shifter mechanism. Snap the shifter/ignition
interlock cable end fitting into the groove in the gear-
shift mechanism.
(7) Adjust the Shifter/Ignition Interlock System.
See Interlock System Adjustment, in this section.
(8) Perform the Shifter/Ignition Interlock System
operation check, as described in the beginning of this
section.
(9) Install console assembly. Refer to Group 23,
Body.
(10) Install screws retaining the gearshift indica-
tor bezel and install bezel and indicator lamp.
(11) Install the gearshift knob set screw and knob.
(12) Install two screws at the upper area of the
column liner and lower left corner.
(13) Snap the clips in at the lower column cover.
Install the three screws along the bottom of the lower
steering column cover and screw on the left outward
face of cover.
(14) Install key cylinder.
(15) Position the shrouds in place. Install the three
lower±to±upper shroud attaching screws through the
bottom of the lower shroud.
(16) Reinstall the ignition lock cylinder into hous-
ing.
(17) Reconnect the battery negative (-) cable to the
vehicle battery.
Fig. 17 Interlock Cable and Connector
Fig. 18 Interlock Cable at Interlock Housing
21 - 62 TRANSAXLEPL
REMOVAL AND INSTALLATION (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)

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)

Record indicator reading for reference when reas-
sembling the transaxle.
Fig. 41 Remove Parking Rod E-Clip
Fig. 42 Parking Rod
Fig. 43 Valve Body Attaching Bolts
Fig. 44 Valve Body and Governor Tubes
Fig. 45 Measure Input Shaft End Play
Fig. 46 Loosen Lock Nut and Tighten Kickdown
Band Adjusting Screw
PLTRANSAXLE 21 - 69
DISASSEMBLY AND ASSEMBLY (Continued)