No start DODGE NEON 2000 Service Repair Manual

against the body and frame rails of the vehicle. As
the crossmember is raised, carefully guide the steer-
ing column lower coupling up through its hole in the
dash panel.
(4) Start the two rear crossmember mounting bolts
into the tapping plates mounted in the body. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 24). The left side bolt is located in the
same location on the other side of the vehicle. Next,
install the two front mounting bolts attaching front
suspension crossmember to frame rails of vehicle.
Lightly tighten all four mounting bolts to a approxi-mately 2 N´m (20 in. lbs.) to hold the front suspen-
sion crossmember in position.
NOTE: When reinstalling the front suspension
crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle's wheel alignment settings
(caster and camber) will be lost.
(5) Using a soft face hammer, tap the front suspen-
sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 25). Once the
front suspension crossmember is correctly positioned,
tighten the rear two crossmember mounting bolts to
a torque of 203 N´m (150 ft. lbs.), then tighten the
front two crossmember mounting bolts to a torque of
142 N´m (105 ft. lbs.).
(6) Fasten the engine torque strut to the right for-
ward corner of the front suspension crossmember
using its mounting bolt (Fig. 24). Follow the proce-
dure described in the ENGINE service manual group
to properly align and tighten the torque strut mount-
ing bolts.
(7) Reconnect the wiring harness connector to the
power steering fluid pressure switch (Fig. 23). Be
sure the locking tab on the wiring harness connector
is securely latched.
(8) Lower the vehicle to ground level.
(9) Install the dash-to-lower coupling seal in place
over the lower coupling's plastic collar.
NOTE: Verify that grease is present on the lip of
the dash-to-coupling seal where it contacts the cou-
pling's plastic collar.
(10) Inside the passenger compartment, reconnect
the steering column lower coupling to the steering
column upper coupling (Fig. 22). Install the coupling
pinch bolt an tighten the pinch bolt nut to a torque of
28 N´m (250 in. lbs.). Install the pinch bolt retainer
pin.
(11) Remove the steering wheel holder.
(12) While looking under the instrument panel at
the lower coupling, rotate the steering wheel back-
and-forth to verify that the lower coupling does not
squeak against the dash-to-coupling seal.
Fig. 26 Crossmember Lowered
1 ± STEERING COLUMN LOWER COUPLING
2 ± POWER STEERING GEAR
3 ± FRONT SUSPENSION CROSSMEMBER
4 ± TRANSMISSION JACK
Fig. 27 Coupling Roll Pin
1 ± STEERING COLUMN LOWER COUPLING
2 ± POWER STEERING GEAR PINION SHAFT
3 ± ROLL PIN
4 ± ROLL PIN PUNCH
19 - 40 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(11) Disconnect the vehicle speed sensor connector
(Fig. 39).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 40).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 40).
(17) Remove bellhousing dust cover (Fig. 40).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 41).
(19) Remove starter motor (Fig. 42).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 43).
Fig. 39 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINION
Fig. 40 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 41 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
PLTRANSAXLE 21 - 15
REMOVAL AND INSTALLATION (Continued)

(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 44).(25) Remove transaxle from vehicle (Fig. 44).
(26) If installing a new or replacement transaxle,
remove the upper mount as shown in (Fig. 45), trans-
fer to the replacement unit and torque all bolts to 68
N´m (50 ft. lbs.) torque.
INSTALLATION
(1) Install clutch module onto input shaft. Install
transaxle into position.
(2) Install transaxle-to-engine mounting bolts (Fig.
44) and tighten to 95 N´m (70 ft. lbs.) torque.
(3) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (80 ft. lbs.) torque (Fig. 43).
(4) Remove screwjack.
(5) Install drive plate-to-clutch module bolts and
torque to 88 N´m (65 ft. lbs.) torque.
(6) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 42).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 40).
(9) Install left engine-to-transaxle bending brace
(Fig. 40).
(10) Install structural collar (Fig. 40) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(11) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 41).
(12) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(13) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(14) Lower vehicle.
(15) Connect vehicle speed sensor connector (Fig.
39).
(16) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 38).
(17) Connect clutch cable to fork and secure to
transaxle (Fig. 37).
(18) Install bellhousing cap (Fig. 37).
(19) Connect back-up lamp switch connector.
(20) Connect ground strap to transaxle upper
mount bracket.
(21) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
Fig. 42 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 43 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 16 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

31TH AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
GENERAL INFORMATION
IN VEHICLE SERVICE.....................55
FLUID REQUIREMENTS...................55
DESCRIPTION AND OPERATION
31TH GENERAL INFORMATION..............55
FLUID LEVEL AND CONDITION..............56
TORQUE CONVERTER CLUTCH.............56
HYDRAULIC CONTROL SYSTEM.............56
PRESSURE SUPPLY SYSTEM...............56
PRESSURE REGULATING VALVES...........56
FLOW CONTROL VALVES..................56
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR........................57
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM..............................57
GEARSHIFT AND PARKING LOCK CONTROLS . . 57
COOLER BYPASS VALVE..................57
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR...................58
GOVERNOR.............................58
DIAGNOSIS AND TESTING
TRANSAXLE PRELIMINARY DIAGNOSIS.......58
ROAD TEST.............................65
HYDRAULIC PRESSURE TESTS.............66
CLUTCH AND SERVO AIR PRESSURE TESTS . . 68
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA.............70
BRAKE TRANSMISSION SHIFT INTERLOCK....70
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE.....70
ALUMINUM THREAD REPAIR...............71
FLUSHING COOLERS AND TUBES...........72
OIL PUMP VOLUME CHECK................72
REMOVAL AND INSTALLATION
GEARSHIFT CABLE.......................73
GEARSHIFT MECHANISM..................76
THROTTLE VALVE (KICKDOWN) CABLE.......77
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE...............................79
INTERLOCK MECHANISM..................82
VEHICLE SPEED SENSOR PINION GEAR......83
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH.........................84TRANSAXLE AND TORQUE CONVERTER......84
PUMP OIL SEAL.........................88
DISASSEMBLY AND ASSEMBLY
TRANSAXLE............................89
VALVE BODY............................91
OIL PUMP.............................104
FRONT CLUTCH........................105
REAR CLUTCH ASSEMBLY................108
FRONT PLANETARY AND ANNULUS
GEAR-RECONDITION...................110
LOW/REVERSE (REAR) SERVO-
RECONDITION........................112
ACCUMULATOR-RECONDITION............113
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................113
TRANSFER SHAFT REPAIR................114
PARKING PAWL.........................121
OUTPUT SHAFT REPAIR..................121
DIFFERENTIAL REPAIR...................129
CLEANING AND INSPECTION
VALVE BODY...........................135
ADJUSTMENTS
GEARSHIFT CABLE......................135
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE.........................136
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM.............................137
BAND ADJUSTMENT.....................138
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS.......................138
BEARING ADJUSTMENT PROCEDURES......138
OUTPUT SHAFT BEARING................139
DIFFERENTIAL BEARING.................139
TRANSFER SHAFT BEARING..............140
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 142
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE.............150
31TH TRANSAXLE TORQUE SPECIFICATIONS . 150
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE.............151
21 - 54 TRANSAXLEPL

CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
WHINE/NOISE RELATED
TO ENGINE SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEARLockup Solenoid, Relay or Wiring
Shorted/Open.Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3
SHIFTSLockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL1. Gearshift Linkage/Cable
Misadjusted.1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.5. Inspect lever assembly and replace if
damaged.
21 - 64 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

CLUTCHES BANDS
LEVER START PARK
FRONT REAR LOCKUPOVER-
RUNNING(KICK-
DOWN)LOW/
REV
POSITION SAFETY SPRAG
FRONT REAR
P Ð PARK X X
R Ð REVERSE X X
N Ð NEUTRAL X
D Ð DRIVE
First X X
Second X X
Third X X X
2 Ð SECOND
First X X
Second X X
1 Ð Low X X
The rear clutch is applied in both the D first gear
and 1 first gear positions. Also, the overrunning
clutch is applied in D first gear and the low/reverse
band is applied in 1 first gear position. If the tran-
saxle slips in D range first gear, but does not slip in
1 first gear, the overrunning clutch is slipping. Simi-
larly, if the transaxle slips in any two forward gears,
the rear clutch is slipping.
Using the same procedure, the rear clutch and
front clutch are applied in D third gear. If the tran-
saxle slips in third gear, either the front clutch or the
rear clutch is slipping. By selecting another gear that
does not use one of those units, the unit that is slip-
ping can be determined. If the transaxle also slips in
reverse, the front clutch is slipping. If the transaxle
does not slip in reverse, the rear clutch is slipping.
The process of elimination can be used to detect
any unit that slips and to confirm proper operation of
good units. Road testing can usually diagnose slip-
ping units, although the actual cause of the problem
may not be detected. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
Therefore, unless the condition is obvious, the tran-
saxle should never be disassembled until hydraulic
pressure tests have been performed.
HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most transaxle problems.Before performing pressure tests, check fluid level
and condition, as well as control cable adjustments.
Fluid must be at operating temperature (150 to 200
degrees F.).
Install an engine tachometer. Raise vehicle on a
hoist that allows front wheels to turn, and position
tachometer so it can be read.
Disconnect throttle cable and shift cable from tran-
saxle levers so they can be controlled from outside
the vehicle.
Attach 150 psi gauges to ports required for test
being conducted. A 300 psi gauge (C-3293) is required
for reverse pressure test at rear servo.
Test port locations are shown in (Fig. 5).
TEST ONE (SELECTOR IN 1)
(1) Attach gauges to line and low-reverse ports.
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle all the way
rearward (1 position).
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
21 - 66 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALTERNATIVE MAINTENANCE METHODS
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION: The use of any fluid exchanger that
introduces additives into the transaxle is not rec-
ommended.
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating tempera-
ture.
(2) Obtain a suitable transaxle fluid exchanger
and verify the tank is clean and dry.
(3) Fill the tank to the recommended fill capacity
with MopartATF+4 Type 9602.
(4) Connect the machine to the vehicle 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 MopartATF+4 Type 9602. Refer
to Fluid Level and Condition Check in this group for
the proper fluid ªtop-offº procedure.
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) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils. This repair consists of drilling out the
worn-out or damaged threads. Then tap the hole with
a Heli-Coil tap, and install a Heli-Coil insert into the
hole. This brings the hole back to its original thread
size.
Heli-Coil tools and inserts are readily available
from most automotive parts suppliers.
Fig. 8 Dipstick Markings
1 ± TRANSAXLE DIPSTICK
PLTRANSAXLE 21 - 71
SERVICE PROCEDURES (Continued)

INSTALLATION
(1) Install cable assembly through floor pan open-
ing and secure to floor pan with grommet plate and
one screw (Fig. 16). Make sure the three grommet
plate studs protrude through cable assembly and
floor pan and tighten screw to 7 N´m (60 in. lbs.).
(2) Route transaxle end of cable assembly into
engine compartment and over transaxle assembly.
(3) Install and tighten intermediate pipe heat
shield front screws.
(4) Install catalytic converter heat shield (Fig. 15).
(5) Install gear shift cable to bracket and connect
to shift lever (Fig. 14).
(6) Install and tighten the three grommet plate-to-
floor pan nuts. Tighten to 6 N´m (50 in. lbs.) torque.
(7) Connect gearshift cable to shifter assembly as
shown in (Fig. 12).
(8) Install shifter bezel (Fig. 11).
(9)Adjust gearshift cable as follows:
(a) Place gearshift lever in the PARK (P) posi-
tion.
(b) Loosen shift cable adjustment screw (Fig.
17).
(c) Verify transaxle is in the PARK (P) position
and the shifter lever is in gated PARK..
(d) Tighten shift cable adjustment screw to 8
N´m (70 in. lbs.) torque.
(10) Install battery tray.
(11) Install battery and hold down clamp.
(12) Install the air cleaner/throttle body assy. (Fig.
13) as follows:(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(13) Install center console assembly (Fig. 10).
(14) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 9).
(15) Connect battery cables.
(16) Verify that engine starter operates in both
PARK (P) and NEUTRAL (N). Starter should not
operate in any other gear position.
Fig. 16 Grommet Plate/Shift Cable at Floor Pan
1 ± GROMMET PLATE
2 ± SHIFT CABLE
Fig. 17 Gearshift Cable Adjustment Screw
1 ± GEARSHIFT CABLE ADJUSTMENT SCREW
PLTRANSAXLE 21 - 75
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)

(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)