service DODGE NEON 2000 Service Repair Manual

STEERING GEAR
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING GEAR..................21
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........22
POWER STEERING GEAR..................22
OUTER TIE ROD.........................26SPECIFICATIONS
POWER STEERING GEAR FASTENER
TORQUE SPECIFICATIONS...............28
SPECIAL TOOLS
POWER STEERING GEAR..................28
DESCRIPTION AND OPERATION
POWER STEERING GEAR
The power steering gear is mounted on the front
suspension crossmember (Fig. 1). The outer ends of
the outer tie rods attach to the steering knuckles.
The power steering gear operates as follows: Turn-
ing of the steering wheel is converted into linear
travel through the meshing of the helical pinion
teeth with the rack teeth of the gear. Power assist
steering is provided by a pump supplying fluid to
either side of the integral rack piston.Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. This movement
directs oil behind the integral rack piston, which, in
turn, builds up hydraulic pressure and assists in the
turning effort.
The drive tangs on the pinion of the power steering
gear mate loosely with a stub shaft. This is to permit
manual steering control to be maintained if the drive
belt on the power steering pump should break. How-
ever, under these conditions, steering effort will be
increased.
Fig. 1 Power Steering Gear
1 ± OUTER TIE ROD
2 ± JAM NUT3 ± STEERING GEAR
4 ± FRONT SUSPENSION CROSSMEMBER
PLSTEERING 19 - 21

NOTE: The power steering gear should not be ser-
viced or adjusted. If a malfunction or oil leak occurs
with the steering gear, the complete steering gear
needs to be replaced.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
POWER STEERING GEAR
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
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. 2). This keeps the clockspring in the proper ori-
entation.
(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. 3) (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) Remove both front tire and wheel assemblies
from the vehicle.
(5) Remove nuts attaching both outer tie rods to
the steering knuckles (Fig. 4). Remove each nut by
holding the tie rod stud stationary while loosening
and removing the nut with a wrench.
(6) Remove the outer tie rod from the steering
knuckles using Remover, Special Tool MB991113
(Fig. 5).
(7) Remove the tie rod heat shield.
Fig. 2 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 3 Steering Column Couplings
1 ± STEERING COLUMN UPPER COUPLING
2 ± PINCH BOLT
3 ± STEERING COLUMN LOWER COUPLING
4 ± BRAKE PEDAL
5 ± NUT
6 ± RETAINER PIN
19 - 22 STEERINGPL
DESCRIPTION AND OPERATION (Continued)

(7) 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. 9). Once the
front suspension crossmember is correctly positioned,
tighten the rear two crossmember (and rear lower
control arm) 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.).
(8) Fasten the engine torque strut to the right for-
ward corner of the front suspension crossmember
using its mounting bolt (Fig. 8). Follow the procedure
described in the ENGINE service manual group to
properly align and tighten the torque strut and it's
mounting bolts.
(9) Using a lint free towel, wipe clean the open
power steering hose ends and the power steering
gear ports. Replace the pressure hose used O-ring
with new. Lubricate the O-ring with power steering
fluid.
(10) Attach the power steering fluid pressure hose
to it's port on the power steering gear (Fig. 7). Start
the tube nut threads into the gear, but do not tighten
them at this time. On vehicles equipped with a power
steering fluid cooler, reconnect the cooler line to the
gear in place of the power steering fluid return hose.
(11) Open the routing clips on the front of the
steering gear housing and install the power steering
fluid pressure hose into the routing clips.
(12) On vehicles equipped with a power steering
fluid cooler, place the cooler in mounting position and
snap the cooler tube going to the gear into the right
routing clip.
(13) Close both routing clips.
(14) Tighten the power steering fluid pressure
hose tube nut at the gear to a torque of 34 N´m (25
ft. lbs.).
(15) If the vehicle is equipped with a power steer-
ing fluid cooler, install the two screws securing the
cooler to the front suspension crossmember. They are
located behind the cooler.
(16) On vehicle's with a power steering fluid cooler,
place the hose clamp on the hose far enough from the
end to clear the steel fitting on the gear. Do the same
for the fluid return hose on a vehicle that is not
equipped with a cooler.
(17) Push either hose listed in the above step onto
the steel fitting, then move and secure the clamp on
the hose past the bead on the steel fitting in the
steering gears outlet port (Fig. 7).
(18) Route the fluid return hose along the front of
the steering gear, clipping it into place in the
C-clamps on the outside of the routing clips on the
front of the power steering gear housing.
(19) Reconnect the wiring harness connector from
the power steering fluid pressure switch (Fig. 6). Besure the locking tab on the wiring harness connector
is securely latched.
(20) Perform the following to each outer tie rod:
²Place the tie rod heat shield on the knuckle's
steering arm, aligning the hole in the shield with the
hole in the knuckle and the tangs on the outside of
the shield with the outside configuration of the steer-
ing arm. The shield should now be facing outboard,
away from the power steering gear and tie rod (Fig.
4).
²Attach the outer tie rod end to its steering
knuckle.
²Start the attaching nut onto the stud of the
outer tie rod.
²While holding the stud of the tie rod stationary
with a wrench, tighten the attaching nut (Fig. 4).
²Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 55 N´m (40 ft.
lbs.).
(21) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N´m
(100 ft. lbs.) torque.
(22) Lower the vehicle to ground level.
(23) 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.
(24) Inside the passenger compartment, reconnect
the steering column lower coupling to the steering
column upper coupling (Fig. 3). Install the coupling
pinch bolt and tighten the pinch bolt nut to a torque
of 28 N´m (250 in. lbs.). Install the pinch bolt
retainer pin.
(25) Remove the steering wheel holder.
(26) 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.
(27) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure which can be
found in the POWER STEERING PUMP section of
this group to properly fill and bleed the power steer-
ing system.
(28) Check for fluid leaks.
(29) Adjust the front toe setting on the vehicle.
Refer to WHEEL ALIGNMENT in the SUSPENSION
service manual group.
OUTER TIE ROD
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
19 - 26 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(9) While holding the stud of the tie rod stationary
with a wrench, tighten the attaching nut (Fig. 14).
(10) Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 75 N´m (55 ft.
lbs.).
(11) Install the tire and wheel assembly.
(12) Lower the vehicle.
(13) Adjust the front toe setting on the vehicle.
Refer to WHEEL ALIGNMENT in the SUSPENSION
service manual group.
SPECIFICATIONS
POWER STEERING GEAR FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
FRONT SUSPENSION CROSSMEMBER:
Front Mounting Bolts..... 142N´m(105 ft. lbs.)
Rear Mounting Bolts..... 203N´m(150 ft. lbs.)
STEERING GEAR:
Mounting Bolts........... 61N´m(45ft.lbs.)
OUTER TIE ROD:
Steering Knuckle Nut...... 55N´m(40ft.lbs.)
TieRodJamNut .......... 75N´m(55ft.lbs.)
POWER STEERING HOSE:
Tube Nuts............... 34N´m(25ft.lbs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover MB991113
19 - 28 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

STEERING COLUMN
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STEERING COLUMN......................29
STEERING COLUMN LOWER COUPLING......29
DIAGNOSIS AND TESTING
STEERING COLUMN......................30
STEERING COLUMN LOWER COUPLING......30
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........31STEERING COLUMN......................31
STEERING COLUMN LOWER COUPLING......38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS.......................41
DESCRIPTION AND OPERATION
STEERING COLUMN
This vehicle is equipped with both tilt and non-tilt
steering columns. Both steering columns have been
designed to be serviced only as complete assemblies
if an internal component is found to be defective (Fig.
1). The shaft, bearings and upper coupling are all
serviced with the column.
The replaceable components on the steering col-
umn assembly are:
²the key cylinder
²the ignition switch
²the multi-function switch
²the clockspring²the trim shrouds
²the steering wheel
²the driver airbag module
These components can be serviced without removal
of the steering column from the vehicle. Refer to the
appropriate group and section of this service manual
for servicing these components separately.
STEERING COLUMN LOWER COUPLING
This vehicle uses a corrugated design lower cou-
pling to connect the steering column to the steering
gear (Fig. 2).
This coupling has a hollow corrugated tube that
allows the coupling to bend rather than collapse
when a vehicle is involved in a collision.
Fig. 1 Steering Column
1 ± UPPER MOUNTING NUTS
2 ± STEERING COLUMN
3 ± LOWER MOUNTING NUTS
Fig. 2 Steering Column Lower Coupling
1 ± FLEX JOINT
2 ± SEAL COLLAR SEALING SURFACE
3 ± TO STEERING COLUMN
4 ± CORRUGATED TUBE SECTION
5 ± TO STEERING GEAR
PLSTEERING 19 - 29

DIAGNOSIS AND TESTING
STEERING COLUMN
For diagnosis of conditions relating to the steering
column, refer to the STEERING SYSTEM DIAGNO-
SIS CHARTS in DIAGNOSIS AND TESTING in the
POWER STEERING section of this service manual
group.
STEERING COLUMN LOWER COUPLING
The steering column coupling must be inspected
whenever a vehicle is involved in an impact or when-
ever any of the following conditions exist:
²whenever a vehicle is involved in a collision
which deploys the air bag, regardless of the extent of
damage done to the vehicle.
²if a vehicle is involved in an impact of the vehi-
cles front suspension or under carriage, which results
in any type of damage to the front suspension cross-
member.
²under any conditions which result in the steer-
ing column assembly or steering column shaft receiv-
ing a force great enough to move the steering column
or shaft forward or rearward in a vehicle.
STEERING COLUMN COUPLING INSPECTION
PROCEDURE
(1) Place the steering wheel in the STRAIGHT-
AHEAD position. Using a steering wheel holding
clamp, lock the steering wheel in place to keep it
from rotating. 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. 3) (the pinch bolt nut is caged
to the coupling and is not removable). Separate the
upper and lower steering column couplings.
(3) Remove the silencer seal enclosing the steering
column coupling (Fig. 4).
(4) Inspect steering column lower coupling in the
following areas for signs of damage:
²Inspect the sealing collar on the lower coupling
(Fig. 5) to ensure the it is not cracked, broken, or
otherwise damaged requiring coupling replacement.
²Inspect the corrugated section (Fig. 5) of the
lower coupling for the following conditions or any
other visible signs of damage.
²Uneven spacing between the corrugations on the
coupling.
²Dings or dents in the corrugations of the cou-
pling or anywhere else on the coupling wall.
²A bend in the corrugated section of the coupling.
²Inspect the lower coupling flex joint for binding.
If any of the preceding conditions exist, the steer-
ing column lower coupling must be replaced.Inspect the steering column upper coupling for
damage or binding. If the upper coupling needs to be
replaced, the steering column must be replaced.
NOTE: Verify that grease is present on the lip of
the dash-to-coupling seal where it contacts the
lower coupling's plastic collar.
(5) If the lower coupling does not require replace-
ment, install the dash panel-to-steering column cou-
pling silencer seal (Fig. 4) back on the vehicle.
Fig. 3 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. 4 Steering Column Coupling Seal
1 ± LOWER STEERING COLUMN COUPLER
2 ± UPPER STEERING COLUMN SHAFT COUPLER
3 ± SILENCER SEAL
4 ± BRAKE PEDAL
19 - 30 STEERINGPL

NOTE: Do not tighten the coupling pinch bolt any-
time the vehicle is not at curb riding height. It may
cause unwanted conditions within the steering col-
umn if the vehicle is suspended in any manner
when the pinch bolt is tightened.
(6) Ensure front wheels of vehicle are positioned
STRAIGHT-AHEAD, then align and attach the steer-
ing column upper coupling to the lower coupling.
Install the coupling pinch bolt (Fig. 3). Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).
(7) Install the coupling pinch bolt retainer pin.
(8) Remove the steering wheel holding clamp.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SOCOULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
WARNING: WHEN HANDLING AN UNDEPLOYED
AIR BAG MODULE DURING SERVICING OF THE
STEERING COLUMN, THE FOLLOWING PRECAU-
TIONS SHOULD BE OBSERVED:
²AT NO TIME SHOULD ANY SOURCE OF ELEC-
TRICITY BE PERMITTED NEAR THE INFLATOR ON
THE BACK OF THE AIR BAG MODULE.
²WHEN CARRYING A LIVE MODULE, THE TRIM
COVER SHOULD BE POINTED AWAY FROM THE
BODY TO MINIMIZE INJURY IF THE MODULE
SHOULD ACCIDENTLY DEPLOY.
²IF THE AIR BAG MODULE IS PLACED ON A
BENCH OR OTHER SURFACE, THE PLASTIC
COVER SHOULD BE FACE-UP TO MINIMIZE MOVE-
MENT, IN CASE OF ACCIDENTAL DEPLOYMENT.
CAUTION: Safety goggles should be worn at all
times when working on steering columns.
CAUTION: Disconnect negative (ground) cable from
the battery, before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
STEERING COLUMN
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
Fig. 5 Lower Coupling Inspection
1 ± FLEX JOINT
2 ± SEAL COLLAR SEALING SURFACE
3 ± TO STEERING COLUMN
4 ± CORRUGAGATED TUBE SECTION
5 ± TO STEERING GEAR
PLSTEERING 19 - 31
DIAGNOSIS AND TESTING (Continued)

(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)

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)

TRANSAXLE
TABLE OF CONTENTS
page page
NV T350 (A-578) MANUAL TRANSAXLE........ 131TH AUTOMATIC TRANSAXLE.............. 54
NV T350 (A-578) MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
GENERAL INFORMATION
NV T350 (A578) MANUAL TRANSAXLE.........1
TRANSAXLE IDENTIFICATION................2
FLUID REQUIREMENTS....................2
SPECIAL ADDITIVES.......................2
SEALANTS..............................2
GEAR RATIOS............................2
GEARSHIFT PATTERN......................3
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES...............3
HARD SHIFTING..........................3
NOISY OPERATION........................3
SLIPS OUT OF GEAR......................3
LOW LUBRICANT LEVEL....................4
FLUID LEAKS............................4
CLUTCH PROBLEMS.......................4
SERVICE PROCEDURES
FLUID DRAIN AND FILL.....................4
REMOVAL AND INSTALLATION
GEARSHIFT KNOB........................4
GEARSHIFT BOOT........................5
GEARSHIFT CABLE ASSEMBLY..............6
GEARSHIFT MECHANISM REPLACEMENT......9
VEHICLE SPEED SENSOR AND DRIVE
PINION...............................11
BACK-UP LAMP SWITCH...................12CROSSOVER LEVER......................12
SELECTOR LEVER.......................12
AXLE SHAFT SEALS......................13
SHIFT SHAFT SEALS......................13
TRANSAXLE............................14
DISASSEMBLY AND ASSEMBLY
TRANSAXLE............................18
INPUT SHAFT...........................31
OUTPUT SHAFT.........................36
DIFFERENTIAL..........................36
SYNCHRONIZER.........................41
SHIFT RAILS OVERHAUL..................42
TRANSAXLE CASE OVERHAUL..............42
CLEANING AND INSPECTION
TRANSAXLE............................48
SYNCHRONIZER.........................48
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE...........49
BEARING ADJUSTMENT PROCEDURE........50
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT..........................50
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS...........51
SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE........52
GENERAL INFORMATION
NV T350 (A578) MANUAL TRANSAXLE
The NV T350 (A-578) transaxle is a fully synchro-
nized (except reverse), constant-mesh transaxle. The
transaxle case is constructed of die-cast aluminum,
and is a two-piece design (bell housing case half and
rear housing case half) with a steel end plate bearing
cover. All forward gears are in constant-mesh witheach other, which eliminates the need to move gears
together for engagement. This feature improves
response and eliminates gear ªclashº noises. The
reverse idler gear is supported and rotates on a spin-
dle idler shaft. Depending on application, a reverse
gear brake/blocking ring is available on some units
for shifting ease.
The NV T350 (A-578) transaxle also incorporates an
open differential, which converts power from the output
shaft pinion gear to the differential ring gear. The dif-
PLTRANSAXLE 21 - 1