key DODGE NEON 2000 Service Repair Manual

(25) Turn the key to OFF and remove the scan tool
from the vehicle.
(26) Test the operation of the horn, wipers and any
other functions that are steering column operated. If
applicable, reset the radio and the clock.
(27) If the steering column is a tilt column, verify
the tilt mechanism operates properly.
(28) Road test the vehicle to ensure proper opera-
tion of the steering system and the speed control sys-
tem.
STEERING COLUMN LOWER COUPLING
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section and in STEERING
GEAR.
REMOVAL
(1) Place the steering wheel in the STRAIGHT-
AHEAD position. Using a steering wheel holder, lock
the steering wheel in place to keep it from rotating
(Fig. 21). This keeps the clockspring in the proper
orientation.
(2) Inside the passenger compartment, remove the
steering column coupling retainer pin, back off the
pinch bolt nut, and remove the steering column cou-
pling pinch bolt (Fig. 22) (the pinch bolt nut is caged
to the coupling and is not removable). Separate the
upper and lower steering column couplings.
(3) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.(4) Release the locking tab on the wiring harness
connector for the power steering fluid pressure
switch before connector removal. Remove the wiring
harness connector from the power steering fluid pres-
sure switch (Fig. 23).
(5) Remove the bolt mounting the engine torque
strut to the right forward corner of the front suspen-
sion crossmember (Fig. 24).
Fig. 21 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 22 Steering Column Couplings
1 ± STEERING COLUMN UPPER COUPLING
2 ± PINCH BOLT
3 ± STEERING COLUMN LOWER COUPLING
4 ± BRAKE PEDAL
5 ± NUT
6 ± RETAINER PIN
Fig. 23 Power Steering Fluid Pressure Switch
1 ± WIRING HARNESS CONNECTOR
2 ± POWER STEERING GEAR
3 ± POWER STEERING FLUID PRESSURE SWITCH
4 ± REAR OF FRONT SUSPENSION CROSSMEMBER
19 - 38 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 132).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise.
(4) Set up dial indicator as shown and record end
play (Fig. 133) (Fig. 134). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear
90 degrees and record a final end play.
(5) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(6) After the end play is measured and adjusted,
replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
tion, refer to Speedometer Drive Gear service in this
section.
SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with theU
facing upward.
(2) Install springs into hub slot (Fig. 135).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 136).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 137).
(6) Line up stop ring tang over the keys in the hub
(Fig. 138). Install stop rings. Center the keys and
balls by pushing on both stop rings.
Fig. 132 Staking Retaining Pin
1 ± PINION SHAFT RETAINING PIN
2 ± SPEEDOMETER DRIVE GEAR
Fig. 133 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
4 ± SIDE GEAR
Fig. 134 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT RAILS OVERHAUL
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.
TRANSAXLE CASE OVERHAUL
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.
The components that are left in the gear cases
when the gear train is pulled out are the:
²Axle shaft seals
Fig. 135 Synchronizer Assembly
1 ± SLEEVE
2 ± BALL
3 ± KEY
4 ± SPRING
5 ± HUB
Fig. 136 Synchronizer Balls
1 ± INPUT SHAFT
2 ± HUB
3 ± KEY
4 ± BALL
Fig. 137 Synchronizer Sleeve
1 ± SLEEVE
2 ± INPUT SHAFT
3 ± KEY
Fig. 138 Keys in Hub
1 ± SNAP RING
2 ± CLUTCH
3 ± KEY
4 ± BALL
5 ± SPRING
21 - 42 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT CROSSOVER SHAFT BUSHING
REMOVAL
(1) Install slide hammer #3752 through the cross-
over bushing.
(2) Thread nut and washer onto slide hammer.
(3) Using the slide hammer, remove the crossover
shaft bushing (Fig. 155).
INSTALLATION
(1) Position the replacement crossover shaft bush-
ing over the crossover shaft bushing bore.
(2) Using an appropriate size deep±well socket,
install the crossover shaft bushing into the bushing
bore.
REAR BEARING OIL FEED TROUGH
The bearing oil feed trough is retained in the case
by a pin that is molded into the case and clips that
are part of the trough (Fig. 156).
REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust wash-
ers. Replace the bearings and cups if the rollers are
worn, chipped, cracked, flat spotted, or brinnelled, or if
the bearing cage is damaged or distorted. Replace the
thrust washers if cracked, chipped, or worn. Replace
the gears if the teeth are chipped, cracked, or worn
thin. Inspect the synchronizers. Replace the sleeve if
worn or damaged in any way. Replace the stop rings if
the friction material is burned, flaking off, or worn.
Check the condition of the synchro keys and springs.
Replace these parts if worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
Fig. 155 Crossover Shaft Bushing Removal
1 ± SLIDE HAMMER
2 ± SHIFTER SHAFT BUSHING
Fig. 156 Oil Feed Trough
1 ± OIL FEED TROUGH
21 - 48 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

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.
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
The Brake Transmission Shifter/Ignition Interlock
(BTSI) is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch. The system locks the shifter into the PARK
position. The interlock system is engaged whenever
the ignition switch is in the LOCK or ACCESSORY
position. An additional electrically activated feature
will prevent shifting out of the PARK position unless
the brake pedal is depressed at least one-half inch. A
magnetic holding device integral to the interlock
cable is energized when the ignition is in the RUN
position. When the key is in the RUN position and
the brake pedal is depressed, the shifter is unlocked
and will move into any position. The interlock systemalso prevents the ignition switch from being turned
to the LOCK or ACCESSORY position, unless the
shifter is in the gated PARK position.
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.
GEARSHIFT AND PARKING LOCK CONTROLS
The transaxle is controlled by alever typegear-
shift incorporated within the console. The control has
six selector lever positions: P (Park), R (Reverse), N
(Neutral), and D (Drive), 2 (Second), and 1 (First).
The parking lock is applied by moving the selector
lever past a gate to the (P) position.Do not apply
the parking lock until the vehicle has stopped;
otherwise, a severe banging noise will occur.
COOLER BYPASS VALVE
Some 31TH transaxles are equipped with a cooler
bypass valve (Fig. 2). The valve is designed to bypass
the transaxle oil cooler circuit in cold weather condi-
tions, or when circuit restriction exceeds 25±30 p.s.i.
The valve consists of an integrated check ball and
spring, and a return tube to carry bypassed oil back
to the pump. The bypass valve is mounted to the
valve body transfer plate and is sealed with a rubber
o-ring seal (Fig. 3).
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.
PLTRANSAXLE 21 - 57
DESCRIPTION AND OPERATION (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 following
operation 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.
BRAKE TRANSMISSION SHIFT INTERLOCK
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. Refer to Brake Transmission Interlock
Removal and Installation or Adjustment in this
Group.
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE
NOTE: Refer to Group 0, Lubrication and Mainte-
nance, or the vehicle owner's manual, for the rec-
ommended maintenance (fluid/filter change)
intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparT
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist (See Lubrication,
Group 0). Place a drain container with a large open-
ing, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body and tighten retaining screws to 5 N´m (40
in. lbs.).
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.
21 - 70 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

(4) Remove shifter bezel (Fig. 31).
(5) Disconnect the shifter/ignition interlock cable
from the shifter lever and bracket as shown in (Fig.
32). Remove the cable core end from the plastic cam
of the shifter mechanism and release cable from
shifter bracket
(6) Remove the steering column lower cover (Fig.
33).
(7) Remove the steering column upper and lower
shrouds (Fig. 34).(8) Disconnect the Brake Transmission Shift Inter-
lock (BTSI) solenoid connector from the interlock
cable (Fig. 35).
(9) Rotate the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 36).
(10) Squeeze the interlock cable locking tab.
Remove the cable from the interlock housing (Fig.
37).
(11) Release cable from retaining clips and remove
through opening under steering column.
Fig. 31 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 32 Interlock Cable at Shifter Assembly
1 ± INTERLOCK CABLE
2 ± SHIFTER ASSEMBLY
Fig. 33 Steering Column Lower Cover
1 ± LOWER COVER
Fig. 34 Steering Column Shrouds
1 ± UPPER SHROUD
2 ± LOWER SHROUD
21 - 80 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

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 through hole in instru-
ment panel below steering column and around to
gear shifter assembly.
(2) Turn the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 36).
(3) Install the interlock cable into the interlock
housing at the steering column (Fig. 38). Verify the
cable snaps into the housing and is fully seated.
(4) Return the ignition key to the ªLOCKº position
(Fig. 36).
(5) Connect the BTSI solenoid connector (Fig. 35).
(6) Install cable into retaining clips as shown in
(Fig. 35).
(7) Install steering column upper and lower
shrouds (Fig. 34).
(8) Install steering column lower cover (Fig. 33).
Fig. 35 Interlock Cable at Steering Column
1 ± IGNITION SWITCH
2 ± CLIP
3 ± INTERLOCK CABLE
4 ± BTSI SOLENOID
Fig. 36 Ignition Key/Switch Positions
1 ± ACC
2 ± LOCK
3 ± OFF
4 ± ON/RUN
5±START
Fig. 37 Interlock Cable and Connector
1 ± IGNITION LOCK CYLINDER
2 ± INTERLOCK CABLE
Fig. 38 Interlock Cable at Interlock Housing
1 ± IGNITION SWITCH
2 ± INTERLOCK CABLE
PLTRANSAXLE 21 - 81
REMOVAL AND INSTALLATION (Continued)

(9) Verify that shifter is in gated ªPARKº.
(10) 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 as shown in (Fig. 32).
(11)Adjust interlock cable/system as follows:
If interlock cable is being replaced, it will come with
an adjustment pin. Remove the pin from the cable
and allow the cable to ªself-adjustº. Lock cable
adjustment by pressing down on the adjuster lock
until bottomed at the cable housing. If interlock cable
is being re-used, no pin will be provided. Pry up on
cable adjuster lock to release and allow cable to ªself-
adjustº. Lock cable adjustment by pressing down on
the adjuster lock until bottomed at the cable housing.
(12)Connect battery negative cable and ver-
ify interlock system operation as follows:
(13) Install shifter bezel (Fig. 31).
(14) Install center console assembly (Fig. 30).
(15) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 29).
INTERLOCK MECHANISM
REMOVAL
(1) Remove the steering column lower cover (Fig.
39).
(2) Remove the steering column upper and lower
shrouds (Fig. 40).
(3) Turn the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 41).
(4) Grasp the interlock cable and connector firmly.
Remove the interlock cable (Fig. 42).(5) Remove the two interlock mechanism-to-steer-
ing column attaching screws (Fig. 43). Remove the
interlock housing.INSTALLATION
(1) Position the interlock housing at steering col-
umn. Install the two interlock mechanism-to-steering
column attaching screws. Torque screws to 3 N´m (21
in. lbs.).
(2) Snap the interlock cable into the housing.
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. 39 Steering Column Lower Cover
1 ± LOWER COVER
Fig. 40 Steering Column Shrouds
1 ± UPPER SHROUD
2 ± LOWER SHROUD
21 - 82 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(3) Install steering column upper and lower
shrouds (Fig. 40).
(4) Install steering column lower cover (Fig. 39).
VEHICLE SPEED SENSOR PINION GEAR
REMOVAL
(1) Remove harness connector from sensor (Fig.
44). Be sure weather seal stays on harness connector.
(2) Remove bolt securing the sensor in the exten-
sion housing (Fig. 44).
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor (Fig. 44).
(5) Inspect pinion gear for damage (missing teeth,
etc.) and replace as necessary.NOTE: When removing vehicle speed sensor for
any reason, a new o-ring MUST be used.
INSTALLATION
(1) Install pinion gear to vehicle speed sensor as
shown in (Fig. 44).
(2) Install sensor to extension housing using a
NEW o-ring.
(3) Tighten bolt to 7 N´m (60 in. lbs.).
(4) Connect harness connector.
Fig. 41 Ignition Key/Switch Positions
1 ± ACC
2 ± LOCK
3 ± OFF
4 ± ON/RUN
5±START
Fig. 42 Interlock Cable
1 ± IGNITION LOCK CYLINDER
2 ± INTERLOCK CABLE
Fig. 43 Interlock Mechanism
1 ± MOUNTING SCREW
2 ± INTERLOCK MECHANISM
Fig. 44 Vehicle Speed Sensor Removal/Installation
1 ± CONNECTOR
2 ± SPEEDO PINION
3 ± O-RING
4 ± SENSOR
PLTRANSAXLE 21 - 83
REMOVAL AND INSTALLATION (Continued)