key DODGE NEON 1999 Service Manual Online

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)

(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)

ADJUSTMENT
(1) Set parking brake.
(2) Remove floor console. Refer to Group 23, Body.
(3) Place gearshift lever in the (PARK) (P) posi-
tion.
(4) Push down on the tab and unsnap the collar at
the shifter cable to allow the cable to be adjusted
(Fig. 196).
(5) Move the gearshift lever on the transaxle to
the PARKposition.
(6) Verify the shift lever and transaxle are in the
PARK position. Rotate collar on the shift cable
adjuster end up until it seats against the plastic
housing. NOTE: If the collar will not rotate to the
fully detented lock position, rotate the collar back to
its initial unlocked position. Position the ATX in the
gated PARK position. Apply a slight load to the shift
lever, fore or aft in vehicle, while simultaneously
rotating the collar upward to the LOCK position. The
collar must seat against the plastic housing to
achieve the required detented lock position. The gear-
shift linkage should now be properly adjusted.
Check adjustment as follows:
(7) Detent position for NEUTRAL and DRIVE
should be within limits of hand lever gate stops.
(8) Key start must occur only when the shift lever
is in PARK or NEUTRAL positions.
THROTTLE PRESSURE CABLE ADJUSTMENT
PROCEDURE
The throttle pressure cable adjustment is very
important to proper transaxle operation. This adjust-
ment positions a valve which controls shift speed,
shift 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,
shifts may 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. 197).
(3) To ensure 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 SYSTEM
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
Fig. 196 Gearshift Cable Adjustment
Fig. 197 Throttle Pressure Cable Adjuster Lock
21 - 100 TRANSAXLEPL
ADJUSTMENTS (Continued)

TRANSAXLE
CONTENTS
page page
DESCRIPTION AND OPERATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM........................ 1
DIAGNOSIS AND TESTING
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM........................ 1REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) CABLE ASSEMBLY................ 2
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM ADJUSTMENT............ 4
DESCRIPTION AND OPERATION
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM
The Brake Transmission Shift Interlock (BTSI)
System, is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch. The BTSI system locks the shifter into the
PARK position. The BTSI system is engaged when-
ever the ignition switch is in the LOCK or ACCES-
SORY position.
An additional electrically activated feature will
prevent shifting out of the PARK position unless the
brake pedal is depressed at least one-half an inch. A
solenoid integrated with the BTSI cable assembly
(Fig. 1) is energized when the ignition switch is in
the RUN position. When the key is in the RUN posi-
tion and the brake pedal is depressed, the shifter is
unlocked and will move into any position. The BTSI
system also prevents the ignition switch from being
turned to the LOCK or ACCESSORY position, unless
the shifter is fully locked into the PARK position.
DIAGNOSIS AND TESTING
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) SYSTEM
If the ignition switch cannot be turned to the
LOCK position, with the shifter in PARK and the
brake pedal depressed, an adjustment of the Brake
Transmission Shift Interlock (BTSI) System may be
required. To adjust the Brake Transmission Shift
Interlock (BTSI) System, follow the procedure in the
Adjustment section of this group.
Fig. 1 BTSI Cable Assembly
PLTRANSAXLE 21 - 1

(12) Position the lower shroud in place. Install the
three lower±to±upper shroud attaching screws
through the bottom of the lower shroud (Fig. 8).
(13) Reconnect the battery negative (-) cable to the
vehicle battery.
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI) 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 the
Brake Transmission Shift Interlock (BTSI) 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 BTSI cable
(Fig. 9).
(11) Place a 1mm (0.040) shim between the larger
diameter portion of the shifter gate pin and the plas-
tic cam (Fig. 9).
(12) The spring on the BTSI cable should automat-
ically 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 BTSI system, check oper-
ation of the Brake Transmission Shift Interlock
(BTSI) System, as described in the beginning of this
section.
Fig. 8 Upper/Lower Shroud
Fig. 9 BTSI Cable Adjuster Lock
21 - 4 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

REAR DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(1) Open door glass.
(2) Pull upward at rear end of outer belt weather-
strip.
(3) Separate outer belt weatherstrip from vehicle
(Fig. 57).
INSTALLATION
Reverse the preceding operation.
REAR DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower window glass.
(3) Remove window regulator crank.
(4) Remove screw from inside arm rest pull cup.
(5) Remove screw from behind inside latch release
handle (Fig. 58).
CAUTION: Pulling on trim panel to disengage fas-
teners will damage the trim panel.
NOTE: Use a fork-type push-in fastener removal
tool.
(6) Disengage push-in fasteners holding trim to
door panel around perimeter of trim panel.
(7) Disengage trim panel from retainer channel in
inner belt weather-strip at top of door by lifting while
jiggling.
(8) Tilt top of trim panel away from door and dis-
engage clip holding latch rod to handle.
(9) Separate latch rod from handle.
(10) Remove trim panel from door.
INSTALLATION
(1) Replace any damaged or missing push in fas-
teners from around perimeter of door trim panel.
(2) Place trim panel in position on door.
(3) Insert latch rod into handle and engage clip.
(4) Engage trim panel into retainer channel at top
of door.
(5) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(6) Install push-in fasteners to attach trim to door
panel around perimeter of trim panel.
(7) Install screw behind inside latch release han-
dle.
(8) Install screw inside arm rest pull cup.
(9) Install window regulator crank.
REAR DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door trim panel and watershield.
(2) Remove door glass.
(3) Loosen bolts holding window regulator crank/
motor to door panel.
(4) Disengage bolt heads from keyhole slots in door
panel.
(5) Loosen bolts holding window regulator lift bar
to door panel.
Fig. 57 Rear Door Outer Belt WeatherstripFig. 58 Rear Door Trim
PLBODY 23 - 25
REMOVAL AND INSTALLATION (Continued)

(6) Disengage bolt heads from keyhole slots in door
panel (Fig. 59).
(7) Remove window regulator from door through
access hole in inner panel.
INSTALLATION
(1) Move window regulator into position and
engage bolt heads into key-hole slots in inner door
panel.
(2) Tighten bolts holding window regulator lift bar
to inner door panel.
(3) Engage window regulator crank/motor bolts
into key-hole slots in door panel.
(4) Tighten window regulator crank/motor bolts.
(5) Install door glass, watershield, and door trim
panel.
REAR SEAT BACK
REMOVAL
(1) Remove rear seat cushion.
(2) Remove bolts holding rear seat back and seat
belts to floor.
(3) Push rear seat back upward to disengage hooks
at top of seat back (Fig. 60).
(4) Separate rear seat from vehicle.
INSTALLATION
(1) Move rear seat back into position in vehicle.
(2) Push seat back downward to engage hooks at
top of seat back.
(3) Install bolts holding rear seat back and seat
belts to floor.
NOTE: The torque specification for the inner seat
belt/rear seat back retaining bolts is 57 N´M (42 ft.
lbs.).
(4) Install rear seat cushion.
REAR SEAT BELT BUCKLE
REMOVAL
(1) Remove rear seat cushion.
(2) Remove rear seat back.
(3) Separate rear seat belt buckle from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT BELT RETRACTOR
REMOVAL
(1) Remove rear seat cushion and back.
(2) Remove seat belt bezel from parcel shelf cover.
(3) Remove rear seat closure panel silencer pad as
necessary to gain access to retractor.
(4) Remove bolt holding seat belt lower anchor to
floor.
(5) Remove bolt holding retractor to rear seat clo-
sure panel (Fig. 61).
(6) Push seat belt bezel and buckle stab through
access hole in parcel shelf.
(7) From in luggage compartment, separate rear
seat belt retractor from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT CUSHION
REMOVAL
(1) Pull upward at each end of the rear seat cush-
ion to disengage retainer loops from cups in floor.
(2) Separate rear seat cushion from vehicle (Fig.
62).
INSTALLATION
(1) Place rear seat cushion in position under bot-
tom of seat back.
Fig. 59 Rear Door Window Regulator
Fig. 60 Rear Seat Back
23 - 26 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Reverse the preceding operation. Adjust inner belt
stabilizer against glass with enough tension to allow
free up and down movement.
WINDOW REGULATORÐ2 DOOR
NOTE: Power and manual door glass regulators are
serviced using the same procedures. For power
window motor service procedures, refer to Group
8S, Power Windows.
REMOVAL
(1) Remove door trim panel and water shield.
(2) Disconnect wire connector to power window
motor, if so equipped.
(3) Remove nuts holding regulator lift channel to
door glass (Fig. 85).
(4) Secure door glass in upward position.
(5) Mark position of rear bolt of roller channel to
inner door panel to aid in installation.
(6) Remove bolt holding rear of roller channel to
door panel.
(7) Loosen bolt holding front of roller channel to
door panel.
(8) Separate roller channel from door panel (Fig.
86).
(9) Loosen bolts holding window regulator to inner
door panel.
(10) Separate bolt heads from key-hole slots in
inner door panel.
(11) Remove window regulator through large hole
in inner door panel (Fig. 87) and (Fig. 88).
(12) Remove power window motor from regulator,
if so equipped. Refer to Group 8S for Power Window
Motor procedure.
Fig. 84Fig. 85 Regulator Lift Channel
Fig. 86 Roller Channel
Fig. 87 Manual Window Regulator
PLBODY 23 - 35
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install power window motor on regulator, if so
equipped. Refer to group 8S for Power Window Motor
procedures.
(2) Move window regulator into position in door
and engage bolt heads into key-hole slots in inner
door panel and tighten bolts.
(3) Install roller channel to door panel.
(4) Install bolt at rear of roller channel. Make sure
that bolt is aligned to mark on inner door panel
made previously.
(5) Tighten front and rear bolts of roller channel.
(6) Install nuts holding regulator lift channel to
door glass.
(7) Adjust door glass as described in this section.
(8) Connect wire connector to power window motor,
if so equipped.
(9) Install door speaker, if so equipped.
(10) Install door trim panel and water shield.
WINDOW REGULATORÐ4 DOOR
NOTE: Power and manual door glass regulators are
serviced using the same procedures. For power
window motor service procedures, refer to Group
8S, Power Windows.
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove door glass.
(3) Disconnect wire connector to power window
motor, if so equipped.
(4) Remove nuts holding top of regulator to inner
door panel.
(5) Remove nuts holding bottom of regulator to
door panel (Fig. 89) and (Fig. 90).
(6) Loosen bolts holding regulator crank/motor to
door panel.(7) Disengage bolts from key hole slots in door
panel.
(8) Remove window regulator from access hole in
door panel.
(9) Remove power window motor from regulator, if
so equipped. Refer to Group 8S for Power Window
Motor procedures.
INSTALLATION
(1) Install power window motor on regulator, if so
equipped. Refer to Group 8S for Power Window
Motor procedures.
(2) Move window regulator into position in door
and engage bolt heads in key-slots in inner door
panel.
(3) Tighten bolts attaching regulator crank/motor
to door panel.
(4) Install nuts holding top and bottom of window
regulator to door panel.
(5) Install door glass. Refer to procedures in this
section to verify and adjust glass alignment.
Fig. 88 Power Window Regulator
Fig. 89 Front Door Manual Window Regulator
Fig. 90 Front Door Power Window Regulator
23 - 36 BODYPL
REMOVAL AND INSTALLATION (Continued)