steering 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)

NOTE: Before removing the front suspension
crossmember from the vehicle, the location of the
crossmember must be scribed on the body of the
vehicle (Fig. 9). Do this so that the crossmember
can be relocated upon reinstallation against the
body of vehicle in the same location as before
removal. If the front suspension crossmember is
not reinstalled in exactly the same location as
before removal, the preset front wheel alignment
settings (caster and camber) will be lost.
(6) Using an awl, scribe a line (Fig. 25) marking
the location of where the front suspension crossmem-
ber is mounted against the body of the vehicle.(7) Position a transmission jack under the center
of the front suspension crossmember and raise it to
support the bottom of the crossmember.
(8) Loosen and completely remove the two front
bolts (one right and one left) attaching the front sus-
pension crossmember to the frame rails of vehicle.
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.
(9) Loosen the two rear bolts (one right and one
left) attaching the front suspension crossmember and
lower control arms to the body of the vehicle until
they release from the threaded tapping plates in the
body of the vehicle. Do not completely remove the
rear bolts because they are designed to disengage
from the body threads yet stay within the lower con-
trol arm rear isolator bushing. This allows the lower
control arm to stay in place on the crossmember. 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.
CAUTION: Lower the steering gear slowly, paying
special attention to the power steering fluid hoses
coming down from the power steering pump. Do
not strain or over extend the hoses coming to the
gear. Damage to the hoses or connecting hardware
could occur.
(10) Lower the front suspension crossmember
using the transmission jack enough to allow suffi-
cient access to the steering column lower coupling
(Fig. 26). When lowering front suspension crossmem-
ber, do not let crossmember hang from lower control
arms or power steering hoses. The weight should be
supported by the transmission jack.
(11) Remove the roll pin securing the steering col-
umn lower coupling to the power steering gear pinion
shaft using a roll pin punch (Fig. 27). Push the steer-
ing column lower coupling up and off of the power
steering gear pinion shaft.
INSTALLATION
(1) Push the column end of the steering column
lower coupling partway up through its hole in the
dash panel, then match the flat on the inside of the
steering column lower coupling to the flat on the
power steering gear pinion shaft and slide the cou-
pling onto the top of the pinion shaft. Align the roll
pin hole in the coupling with the groove in the pinion
shaft and install the roll pin through the coupling
until it is centered (Fig. 27).
(2) Center the power steering gear rack in its
travel.
(3) Using the transmission jack, raise the front
suspension crossmember and power steering gear
until the crossmember contacts its mounting spot
Fig. 24 Mounting Bolts
1 ± FRONT SUSPENSION CROSSMEMBER MOUNTING BOLTS
2 ± ENGINE TORQUE ISOLATOR STRUT MOUNTING BOLT
3 ± FRONT SUSPENSION CROSSMEMBER
Fig. 25 Marking Crossmember Location
1 ± SCRIBED LINE
2 ± FRONT SUSPENSION CROSSMEMBER
3±AWL
4 ± BODY
PLSTEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)

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)

SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STEERING WHEEL:
Retaining Nut............ 61N´m(45ft.lbs.)
Airbag Mounting Screws.... 10N´m(90in.lbs.)
Speed Control Switch Screws . 2 N´m (20 in. lbs.)
STEERING COLUMN:
Mounting Nuts.......... 17N´m(150 in. lbs.)
SKIM Mounting Screws..... 3N´m(25in.lbs.)
STEERING COLUMN LOWER COUPLING:
Pinch Bolt.............. 28N´m(250 in. lbs.)
PLSTEERING 19 - 41

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)

(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)

signals when the vehicle is equipped with Anti-Lock
Brakes.
The use of tires from different manufactures on the
same vehicle is NOT recommended. The proper tire
pressure should be maintained on all four tires.
SPARE TIRE±TEMPORARY
The temporary spare tire is designed for emer-
gency use only. The original tire should be repaired
or replaced at the first opportunity, then reinstalled.
Do not exceed speeds of 50 M. P. H. when using the
temporary spare tire. Refer to Owner's Manual for
complete details.
REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capabilityIt is recommend that tires equivalent to the origi-
nal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
TREAD WEAR INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 3).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
Fig. 2 Tire Identification
Fig. 3 Tread Wear Indicators
1 ± TREAD ACCEPTABLE
2 ± TREAD UNACCEPTABLE
3 ± WEAR INDICATOR
PLTIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)