pressure DODGE NEON 2000 Service Repair Manual

Fig. 101 Pressure Regulators and Manual Controls
1 ± VALVE BODY
2 ± LINE PRESSURE VALVE
3 ± SPRING
4 ± ADJUSTING SCREW
5 ± SCREW
6 ± GUIDE7 ± SPRING
8 ± KICKDOWN VALVE
9 ± SPRING
10 ± MANUAL VALVE
11 ± THROTTLE VALVE
21 - 100 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 103 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 ± CONVERTER PRESSURE CONTROL VALVE
2 ± END COVER
3 ± SCREW (3)4 ± REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING
5 ± REGULATOR VALVE THROTTLE PRESSURE PLUG
6 ± SWITCH VALVE
21 - 102 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DISASSEMBLY
Fig. 112 Rear Clutch Outer Snap Ring
1 ± SCREWDRIVER
2 ± SNAP RING
3 ± REAR CLUTCH ASSEMBLY
Fig. 113 Rear Clutch (4-Disc Shown)
1 ± REAR CLUTCH RETAINER
2 ± CLUTCH PLATES
3 ± THICK STEEL PLATE
4 ± SNAP RING (SELECTIVE)
5 ± DRIVING DISCS
6 ± PRESSURE PLATE
Fig. 114 Piston Spring Waved Snap Ring
1 ± REAR CLUTCH RETAINER
2 ± PISTON SPRING
3 ± SCREWDRIVER
4 ± WAVED SNAP RING
Fig. 115 Rear Clutch Piston and Piston Spring
1 ± INPUT SHAFT
2 ± REAR CLUTCH RETAINER
3 ± PISTON SPRING
4 ± WAVED SNAP RING
5 ± PISTON
6 ± PISTON SEALS
PLTRANSAXLE 21 - 109
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)

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

BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The kickdown band adjusting screw is located on
left side (top front) of the transaxle case.
(1) Loosen locknut and back±off nut approximately
five turns. Test adjusting screw for free turning in
the transaxle case.
(2) Using wrench, tighten adjusting screw to 8
N´m (72 in. lbs.).
(3) Back±off adjusting screw the number of turns
listed in Specifications. Hold adjusting screw in this
position and tighten locknut to 47 N´m (35ft. lbs.)
LOW/REVERSE BAND (REAR)
To adjust low/reverse band, proceed as follows:
(1) Loosen and back off locknut approximately five
turns.
(2) Using an inch-pound torque wrench, tighten
adjusting screw to 5 N´m (41 in. lbs.) true torque.
(3) Back±off adjusting screw the number of turns
listed under Specifications. A chart is located at the
rear of this section.
(4) Tighten locknut to 14 N´m (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect andcorrect throttle pressure adjustment before adjusting
the line pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to
obtain specified line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
BEARING ADJUSTMENT PROCEDURES
(1) Take extreme care when removing and install-
ing bearing cups and cones.Use only an arbor
press for installation, as a hammer may not
properly align the bearing cup or cone.Burrs or
nicks on the bearing seat will give a false end play
reading, while gauging for proper shims. Improperly
seated bearing cup and cones are subject to low-mile-
age failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress.
(3) If distress is seen on either the cup or bearing
rollers, both cup and cone must be replaced.
NOTE: Bearing end play and drag torque specifica-
tions must be maintained to avoid premature bear-
ing failures.
(4) Used (original) bearing may lose up to 50 per-
cent of the original drag torque after break-in.
NOTE: All bearing adjustments must be made with
no other component interference or gear inter-
mesh, except the transfer gear bearing.
(5) Refer to the conversion chart in specifications
to convert inches to millimeter measurements. Refer
to bearing shim chart for proper shim thicknesses.
Fig. 221 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
21 - 138 TRANSAXLEPL
ADJUSTMENTS (Continued)

SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
Type .........Automatic three speed with torque
converter and integral differential
Torque Converter Diameter...... 241millimeters
(9.48 in.)
OilType .....................MopartATF+4
(Automatic Transmission Fluid) Type 9602
Cooling Method.... Water Heat Exchanger and/or
air to oil heat exchanger
Lubrication . . . Pump (internal-external gear-type)
Transmission Gear Ratios
First Gear............................2.69
Second Gear...........................1.55
Third Gear............................1.00
Reverse Gear..........................2.10
Band Adjustment
KickdownÐBacked Off From 8 N²m
(72 in. lbs.).................... 21/4Turns
Low-ReverseÐBacked Off From 5 N²m
(41 in. lbs.).................... 31/2Turns
Clutch Pack Clearances
Front Clutch (Not Adjustable)......1.27-2.79mm
(0.050-0.110 in.)
Rear Clutch.......0.71-1.10mm (0.028-0.043 in.)
End Play
Input Shaft........0.19±1.50 mm (.008±.060 in.)
Front Clutch Retainer...........0.76±2.69 mm
(.030±.106 in.)
Front Carrier.......0.89±1.45 mm (.007±.057 in.)
Front Annulus Gear . . 0.09±0.50 mm (.0035±.020 in.)
Planet Pinion.......0.15±0.59 mm (.006±.023 in.)
Reverse Drum......0.76±3.36 mm (.030±.132 in.)
Oil Pump Clearances
Outer Gear To Pocket...........0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . 6 to 12 in. lbs. Drag Torque
Output Hub.......... 0to3in.lbs. Drag Torque
Transfer Shaft.......0.002 to 0.010 in. End Play
Overall Drag At Output
Hub ............. 3to16in.lbs. Drag TorqueThrust Washers
Reaction Shaft Support (No. 1).....1.55±1.60 mm
(.061±.063 in.)
Rear Clutch Retainer (No. 2)......1.55±1.60 mm
(.061±.063 in.)
Output Shaft (No. 3) (Select)......1.98±2.03 mm
(.077±.080 in.)
Output Shaft (No. 3) (Select)......2.15±2.22 mm
(.085±.087 in.)
Output Shaft (No. 3) (Select)......2.34±2.41 mm
(.092±.095 in.)
Front Annulus (No. 4)............2.95±3.05 mm
(.116±.120 in.)
Front Carrier (Nos. 5&6).........1.22±1.28 mm
(.0948±.050 in.)
Sun Gear-Front (No. 7)...........0.85±0.91 mm
(.033±.036 in.)
Sun Gear-Rear (No. 8)...........0.85±0.91 mm
(.033±.036 in.)
Rear Carrier (Nos. 9&10).........1.22±1.28 mm
(.0948±.050 in.)
Rev. Drum (No. 11) . . 1.55±1.60 mm (.061±.063 in.)
31TH TRANSAXLE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Bell Housing Cover Bolts.... 12N´m(105 in. lbs.)
Cooler Line Clamps.......... 2N´m(18in.lbs.)
Diff. Bear. Ret. To Case Bolt . . 34 N´m (300 in. lbs.)
Diff. Cover To Case Bolt..... 19N´m(165 in. lbs.)
Exten. Hous. To Case Bolt . . . 28 N´m (250 in. lbs.)
Drive Plate To Crankshaft
Bolts................... 95N´m(70ft.lbs.)
Drive Plate To Torque Conv.
Bolts................... 88N´m(65ft.lbs.)
Fluid Filter Screw........... 5N´m(45in.lbs.)
Governor Counterweight
Screw................. 28N´m(250 in. lbs.)
Governor To Support Bolt...... 7N´m(60in.lbs.)
Kickdown Band Adj. Lock Nut . . 47 N´m (35 ft. lbs.)
Left Motor Mount Bolts....... 54N´m(40ft.lbs.)
Manual Cable To Trans.
Case Bolt.............. 28N´m(250 in. lbs.)
Manual Control Lever Screw . . 12 N´m (105 in. lbs.)
Oil Pan To Trans. Case
Screw................. 19N´m(165 in. lbs.)
Output Gear Strap Bolts...... 23N´m(17ft.lbs.)
Output Shaft Nut......... 271N´m(200 ft. lbs.)
Park/Neutral Switch......... 34N´m(25ft.lbs.)
Pressure Check Plug......... 5N´m(45in.lbs.)
Pump To Case Bolts........ 31N´m(275 in. lbs.)
Reaction Shaft Assembly
Bolt................... 28N´m(250 in. lbs.)
Rear Cover To Case Screw . . . 19 N´m (165 in. lbs.)
Reverse Band Adj. Lock Nut . . 14 N´m (125 in. lbs.)
21 - 150 TRANSAXLEPL

DESCRIPTION TORQUE
Reverse Band Shaft Plug...... 7N´m(60in.lbs.)
Ring Gear Screw............ 95N´m(70ft.lbs.)
Speedo. To Ext. Hous. Screw . . . 7 N´m (60 in. lbs.)
Sprag Ret. To Transfer Case
Bolt................... 28N´m(250 in. lbs.)
Starter To Trans. Bell Bolts . . . 54 N´m (40 ft. lbs.)
Stirrup Strap Ret. Bolts..... 23N´m(200 in. lbs.)
Trans. To Cyl. Block Bolt...... 95N´m(70ft.lbs.)
Transfer Shaft Nut........ 271N´m(200 ft. lbs.)
Transfer Gear Strap Bolts..... 23N´m(17ft.lbs.)
Valve Body Assy. To Case
Bolts.................. 12N´m(105 in. lbs.)
Valve Body Screw............ 5N´m(45in.lbs.)
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE
Puller Press Extension C-293-3
Adapter Blocks C-293±36
Adapter Blocks C-293±52
Puller Press C-293±PA
Slide Hammer C-637
Pressure Gauge (Low) C-3292
Pressure Gauge (High) C-3293SP
Dial Indicator C-3339
PLTRANSAXLE 21 - 151
SPECIFICATIONS (Continued)

TIRES AND WHEELS
TABLE OF CONTENTS
page page
TIRES................................... 1WHEELS................................ 10
TIRES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
TIRE...................................1
RADIAL-PLY TIRES........................2
SPARE TIRE±TEMPORARY..................3
REPLACEMENT TIRES.....................3
DIAGNOSIS AND TESTING
TREAD WEAR INDICATORS.................3
TIRE WEAR PATTERNS.....................4
TIRE NOISE OR VIBRATION.................4
VEHICLE LEAD DIAGNOSIS AND
CORRECTION..........................4
SERVICE PROCEDURES
PRESSURE GAUGES......................6TIRE INFLATION PRESSURES...............6
TIRE PRESSURE FOR HIGH SPEED
OPERATION............................6
TIRE AND WHEEL ROTATION................6
REPAIRING TIRE LEAKS....................7
TIRE AND WHEEL MATCH MOUNTING.........7
CLEANING AND INSPECTION
CLEANING TIRES.........................9
SPECIFICATIONS
TIRE SPECIFICATIONS.....................9
DESCRIPTION AND OPERATION
TIRE
Tires are designed and engineered for each specific
vehicle (Fig. 1). They provide the best overall perfor-
mance for normal operation. The ride and handling
characteristics match the vehicle's requirements.
With proper care they will give excellent reliability,
traction, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
PLTIRES AND WHEELS 22 - 1