DODGE NEON 2000 Service Repair Manual

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. 188).
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.)
(Fig. 189).
(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
Fig. 187 Checking Bearing Turning Torque
1 ± OUTPUT SHAFT GEAR
2 ± TORQUE WRENCHFig. 188 Turn Stirrup Clockwise Against Flats Of
Retaining Nut
1 ± TURN STIRRUP CLOCKWISE
2 ± STRAP
Fig. 189 Tighten Strap Retaining Nuts
1 ± STRAP
2 ± OUTPUT GEAR
3 ± STIRRUP
21 - 128 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for
differential repair and bearing turning torque check-
ing.
Fig. 190 Remove Extension Seal
1 ± EXTENSION HOUSING
2 ± SMALL CHISEL
3 ± HAMMER
4 ± OIL SEAL
Fig. 191 Install New Seal into Extension
1 ± SPECIAL TOOL L-4520 (INVERTED)
2 ± HANDLE C-4171
3 ± HAMMER
4 ± EXTENSION HOUSING
Fig. 192 Differential Cover Bolts
1 ± DIFFERENTIAL COVER
2 ± DIFFERENTIAL COVER BOLT
Fig. 193 Remove or Install Differential Cover
1 ± GOVERNOR PRESSURE PLUG
2 ± DIFFERENTIAL COVER
3 ± 1/8 INCH BEAD OF R T V SEALANT
4 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 129
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential cover.
Fig. 194 Remove Bearing Retainer Axle Seal
1 ± SPECIAL TOOL 7794A
2 ± SPECIAL TOOL C-637
3 ± DIFFERENTIAL BEARING RETAINER
Fig. 195 Install Bearing Retainer Axle Seal
1 ± SPECIAL TOOL L-4520
2 ± SPECIAL TOOL C-4171
Fig. 196 Differential Bearing Retainer Bolts
1 ± DIFFERENTIAL BEARING RETAINER
2 ± DIFFERENTIAL BEARING RETAINER BOLTS (6)
Fig. 197 Remove or Install Bearing Retainer
1 ± GOVERNOR PRESSURE PLUG
2 ± DIFFERENTIAL BEARING RETAINER
3 ± SPECIAL TOOL L-4435
21 - 130 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential bearing retainer.
Fig. 198 Differential Bearing Retainer (Typical)
1 ± DIFFERENTIAL BEARING CUP
2 ± DIFFERENTIAL
3 ± DIFFERENTIAL BEARING RETAINER
Fig. 199 Extension Bolts
1 ± EXTENSION HOUSING BOLTS (4)
2 ± EXTENSION HOUSING
3 ± OIL SEAL
Fig. 200 Remove or Install Extension Housing
1 ± EXTENSION HOUSING
2 ± DIFFERENTIAL ASSEMBLY
3 ± SPECIAL TOOL L-4435
Fig. 201 Differential and Extension
1 ± EXTENSION HOUSING
2 ± ªOº RING
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 131
DISASSEMBLY AND ASSEMBLY (Continued)

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use MopartSilicone Rubber Adhesive Sealant, or
equivalent, when installing extension housing.
Fig. 202 Remove Differential Bearing Cone
(Extension Housing Side)
1 ± SPECIAL TOOL C-293
2 ± SPECIAL TOOL C-293-36
3 ± SPECIAL TOOL C-293-3
Fig. 203 Position Bearing Cone Onto Differential
1 ± DIFFERENTIAL ASSEMBLY
2 ± DIFFERENTIAL BEARING
Fig. 204 Install Differential Bearing Cone
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL 6536
3 ± DIFFERENTIAL ASSEMBLY
Fig. 205 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
1 ± SPECIAL TOOL L-4539-2
2 ± SPECIAL TOOL 5048
3 ± SPECIAL TOOL 5048-4
21 - 132 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

To install the differential bearing cup and cone on
the ring gear side, use Special Tool 5052, and Special
Tool C-4171.NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
CAUTION: Side gear end play must be BETWEEN
0.001 to 0.013 inch.
Fig. 206 Position Tool 5048 Over Button and Collets
at Differential Bearing
1 ± SPECIAL TO0L 5048
2 ± DIFFERENTIAL
3 ± SPECIAL TOOL 5048-4
Fig. 207 Remove Differential Bearing Cone
1 ± SPECIAL TOOL 5048
2 ± RING GEAR
Fig. 208 Checking Side Gear End Play
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
4 ± SIDE GEAR
Fig. 209 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 133
DISASSEMBLY AND ASSEMBLY (Continued)

To remove the differential bearing cup from the
extension housing/adapter side, use Special Tool
6062A, Remover. To install the differential bearing
cup on the extension housing/adapter side, use Spe-
cial Tool 6536, Driver and Special Tool C-4171, Han-
dle.
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
Fig. 210 Differential Bearing Retainer
1 ± DIFFERENTIAL BEARING CUP
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 211 Position Bearing Cup Remover Tool in
Retainer
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 212 Remove Bearing Cup
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 213 Install Bearing Cup
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL 5052
3 ± DIFFERENTIAL BEARING RETAINER
21 - 134 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

CLEANING AND INSPECTION
VALVE BODY
Allow all parts to soak a few minutes in a suitable
clean solvent. Wash thoroughly and blow dry with
compressed air. Be sure all passages are clean and
free from obstructions.
Inspect manual and throttle valve operating levers
and shafts for being bent, worn or loose. If a lever is
loose on its shaft, it should be replaced. Do not
attempt to straighten bent levers.
Inspect all mating surfaces for burrs, nicks and
scratches. Minor blemishes may be removed with cro-
cus cloth, using only a very light pressure. Using a
straightedge, inspect all mating surfaces for warpage
or distortion. Slight distortion may be corrected,
using a surface plate. Be sure all metering holes in
steel plate are open. Using a penlight, inspect bores
in valve body for scores, scratches, pits, and irregu-
larities.
Inspect all valve springs for distortion and col-
lapsed coils. Inspect all valves and plugs for burrs,
nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is
taken not to round off sharp edges. The sharpness of
these edges is vitally important. It prevents foreign
matter from lodging between valve and valve body.
This reduces the possibility of sticking. Inspect all
valves and plugs for freedom of operation in valve
body bores.
When bores, valves, and plugs are clean and dry,
the valves and plugs should fall freely in the bores.
The valve body bores do not change their dimensions
with use. Therefore, a valve body that was function-
ing properly when vehicle was new, will operate cor-
rectly if it is properly and thoroughly cleaned. There
is no need to replace a valve body unless it is dam-
aged in handling.
ADJUSTMENTS
GEARSHIFT CABLE
Normal operation of the Park/Neutral Position
Switch provides a quick check to confirm proper link-
age adjustment. The engine starter should only oper-
ate when the transaxle shift lever is in the PARK (P)
or NEUTRAL (N) positions.
If the engine starts in any other gear position, or
the vehicle rolls when the shifter is in gated PARK
(P), a gearshift cable adjustment is necessary.
ADJUSTMENT
(1) Loosen set screw and remove knob from shifter
handle (Fig. 214).(2) Remove the center console assembly as shown
in (Fig. 215).
(3)Adjust gearshift cable as follows:
(a) Place gearshift lever in the PARK (P) posi-
tion.
(b) Loosen shift cable adjustment screw (Fig.
216).
(c) Move transaxle manual lever to the PARK.
Verify transaxle is in PARK by attempting to roll
vehicle in either direction.
Fig. 214 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 215 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
PLTRANSAXLE 21 - 135

(d) Tighten shift cable adjustment screw to 8
N´m (70 in. lbs.) torque.
(4) Verify proper cable adjustment. Engine should
start with the shifter lever in PARK (P) and NEU-
TRAL (N) positions ONLY.
(5) Install center console assembly (Fig. 215).
(6) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 214).
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE
The transmission throttle valve is operated by a
cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine
throttle body lever.
The throttle valve is located within the transaxle
valve body and is responsible for transaxle shift
speed, shift quality, and part-throttle downshift sen-
sitivity. Proper cable adjustment is essential for
proper transaxle operation.
NOTE: The air cleaner/throttle body assembly must
be installed into position before making this adjust-
ment.
(1) Verify cable is routed properly with no kinked
or binding conditions.(2) Release adjustment locking clip on cable at
throttle body.It is not necessary to remove clip.
(3) Grab cable conduit near adjustment body, push
in towards throttle body, then release grip (Fig. 217).
This allows cable to self adjust.
(4) Press locking clip to secure cable position (Fig.
218).
(5) Road test vehicle to verify proper transaxle
operation.
Fig. 216 Gearshift Cable Adjustment Screw
1 ± GEARSHIFT CABLE ADJUSTMENT SCREW
Fig. 217 Throttle Valve Cable Adjustment
1 ± TAB UNLOCKED
Fig. 218 Cable Locking Clip
1 ± TAB LOCKED
2 ± THROTTLE VALVE CABLE
21 - 136 TRANSAXLEPL
ADJUSTMENTS (Continued)

BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
VERIFICATION
The following chart describes the normal operation
of the Brake Transmission Shift Interlock (BTSI) sys-
tem. If the ªexpected responseº differs from the vehi-
cle's response, then system repair and/or adjustment
is necessary.
ADJUSTMENT
(1) Loosen set screw and remove knob from shifter
handle (Fig. 219).
(2) Remove the center console assembly as shown
in (Fig. 220).
(3) Remove shifter bezel (Fig. 221).
(4)Adjust interlock cable/system as follows:
Pry up on cable adjuster lock to release and allow
cable to ªself-adjustº. Lock cable adjustment by press-
ing down on the adjuster lock until bottomed at the
cable housing.
(5) Verify correct system operation. Refer to verifi-
cation procedure.
(6) Install shifter bezel (Fig. 221).
(7) Install center console assembly (Fig. 220).
(8) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 219).
ACTION EXPECTED RESPONSE
1. Turn key to the ªOFFº
position.1. Shifter CAN be shifted
out of park.
2. Turn key to the
9ON/RUNº position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
ªON/RUNº position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the ªLOCKº or9ACCº
position.4. Key cannot be
returned to the ªLOCKº or
ªACCº position.
5. Return shifter to
ªPARKº and try to remove
the key.5. Key can be removed
(after returning to ªLOCKº
position).
6. With the key removed,
try to shift out of ªPARKº.6. Shifter cannot be
shifted out of ªPARKº.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
Fig. 219 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 220 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
PLTRANSAXLE 21 - 137
ADJUSTMENTS (Continued)