torque DODGE NEON 2000 Service Repair Manual

(2) Disconnect throttle valve cable from air clean-
er/throttle body assembly as shown in (Fig. 25).
(3) Disconnect throttle valve cable from lever on
transaxle and remove from bracket (Fig. 26).INSTALLATION
NOTE: Route throttle valve cable in a manner that
allows free, unobstructed travel. For proper tran-
saxle operation, the cable must not bind.
(1) Install transaxle throttle valve cable to bracket
and lever as shown in (Fig. 26). Make sure the cable
snapsonto the lever.
(2) Install the throttle valve cable to the air clean-
er/throttle body as shown in (Fig. 25).
(3) Install the air cleaner/throttle body assy. as fol-
lows:
(a) 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.
(b) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(c) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(d) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(4) Connect the battery negative cable.
(5) Perform the Throttle Valve Cable Adjustment
Procedure found in this group.
(6) Road test vehicle and verify proper transaxle
operation.
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE
The transmission throttle valve is operated by a
cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine
throttle body lever.
The throttle valve is located within the transaxle
valve body and is responsible for transaxle shift
speed, shift quality, and part-throttle downshift sen-
sitivity. Proper cable adjustment is essential for
proper transaxle operation.
NOTE: The air cleaner/throttle body assembly must
be installed into position before making this adjust-
ment.
Fig. 25 Throttle Valve Cable at Air Cleaner/Throttle
Body
1 ± KICKDOWN CABLE
2 ± AIR CLEANER/THROTTLE BODY ASSY.
Fig. 26 Throttle Valve Cable at Transaxle
1 ± LEVER
2 ± BRACKET
3 ± KICKDOWN CABLE
21 - 78 TRANSAXLEPL
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)

PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH
TEST
The park/neutral starting switch is the center ter-
minal of the three terminal switch. It provides
ground for the starter solenoid circuit through the
selector lever in PARK and NEUTRAL positions only.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in PARK or NEUTRAL.
(2) Check gearshift cable adjustment before replac-
ing a switch that tests bad.
REMOVAL
(1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
PARK, then to NEUTRAL position, and inspect to see
the switch operating lever fingers are centered in
switch opening.
INSTALLATION
(1) Screw the switch with a new seal into tran-
saxle case and tighten to 33 N´m (24 ft. lbs.). Retest
switch with the test lamp.
(2) Add fluid to transaxle to bring up to proper
level.
(3) The back-up lamp switch circuit is through the
two outside terminals of the three terminal switch.
(4) To test switch, remove wiring connector from
switch and test for continuity between the two out-
side pins.
(5) Continuity should exist only with transaxle in
REVERSE position.
(6) No continuity should exist from either pin to
the case.
TRANSAXLE AND TORQUE CONVERTER
REMOVAL
(1) Raise hood.
(2) Disconnect both battery cables, remove battery
hold down clamp and bolt, and remove battery.
(3) Remove air cleaner/throttle body assy. (Fig. 45)
as follows:
(a) Disconnect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(b) Disconnect the Throttle Position Sensor
(TPS) and Idle Air Control (IAC) connectors.
(c) Remove mounting bolt and nut (Fig. 45) and
partially remove air cleaner assembly.
(d) Disconnect accelerator, transaxle kickdown,
and speed control (if equipped) cables after the
assy. is removed from position. Remove air cleaner
assembly from vehicle.(4) Remove battery tray from bracket.
(5) Disconnect torque converter clutch solenoid and
neutral safety/back-up lamp switch connectors.
(6) Disconnect and plug transaxle oil cooler lines
(Fig. 46).
(7) Disconnect shifter cable from shift lever and
remove from bracket (Fig. 47). Secure cable out of the
way.
Fig. 45 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
Fig. 46 Transaxle Oil Cooler Lines
1 ± RETURN
2 ± CLAMPS
3 ± PRESSURE
21 - 84 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(14) Remove structural collar (Fig. 51).
(15) Remove the left engine-to-transaxle lateral
bending brace (Fig. 51).
(16) Remove bellhousing dust cover (Fig. 51).
(17) Remove starter motor (Fig. 52).
(18) Remove drive plate to converter bolts (Fig.
54).
(19) Support engine at oil pan with screw jack and
wood block.
(20) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 53).
(21) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(22) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 54).
(23) Remove transaxle from vehicle (Fig. 54).
(24) Remove torque converter from front pump.
(25) If installing a new or replacement transaxle,
remove the upper mount and bracket as shown in
(Fig. 55), and transfer to the replacement unit and
torque all bolts to 68 N´m (50 ft. lbs.) torque.
Fig. 51 Left Lateral Bending Brace and Structural
Collar
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 52 Starter Motor Removal/Installation
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 53 Transaxle Upper Mount and Bracket
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 86 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install torque converter into front pump.
Rotate converter until the hub fully engages front
pump gear lugs.
(2) Install transaxle-to-engine mounting bolts (Fig.
54) 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. 53).
(4) Remove screwjack.
(5) Install converter-to-drive plate 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. 52).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 51).
(9) Install left engine-to-transaxle bending brace
(Fig. 51).
(10) Install structural collar (Fig. 51) 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.
Fig. 54 Transaxle Removal/Installation
1 ± CLIP
2 ± BOLT (3)3 ± TRANSAXLE
4 ± CONVERTER BOLT (4)
Fig. 55 Transaxle Upper Mount and Bracket
1 ± MOUNT
2 ± TRANSAXLE
PLTRANSAXLE 21 - 87
REMOVAL AND INSTALLATION (Continued)

(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 both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(12) Connect vehicle speed sensor connector (Fig.
50).
(13) Install right lateral bending brace and tighten
bolts to 81 N´m (60 ft. lbs.) torque.
(14) Lower vehicle.
(15) Connect transaxle cooler lines and tighten
clamps (Fig. 46).
(16) Connect torque converter clutch solenoid and
neutral safety/back-up lamp switch connectors.
(17) Install transaxle dipstick tube.
(18) Install gear shift cable to bracket and connect
to shift lever (Fig. 47).
(19) Install transaxle kickdown cable to bracket
and lever as shown in (Fig. 48).
(20) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
(21) Install the air cleaner/throttle body assy. as
follows:
(a) Connect the accelerator, transaxle kickdown,
and speed control (if equipped) cables to the air
cleaner/throttle body assy.
(b) Install assy into position and tighten fasten-
ers to 14 N´m (120 in. lbs.) torque.
(c) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(d) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(22) Fill transaxle with a suitable amount of
ATF+4.
(23) Road test vehicle.
(24) Check for leaks, inspect fluid level, and adjust
as necessary.
PUMP OIL SEAL
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly
from the transaxle case.
REMOVAL
(1) Screw seal remover Tool C-3981-B into seal
(Fig. 56), then tighten screw portion of tool to with-
draw the seal.
INSTALLATION
(1) To install a new seal, place seal in opening of
the pump housing (lip side facing inward). Using Tool
C-4193 and Handle Tool C-4171, drive new seal into
housing until tool bottoms (Fig. 57).
Fig. 56 Remove Pump Oil Seal
1 ± PUMP OIL SEAL
2 ± OIL SEAL REMOVER TOOL C-3981-B
3 ± OIL PUMP
Fig. 57 Install Pump Oil Seal
1 ± OIL PUMP
2 ± OIL SEAL INSTALLER TOOL C-4193
3 ± SPECIAL TOOL HANDLE C-4171
21 - 88 TRANSAXLEPL
REMOVAL AND INSTALLATION (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)

Fig. 104 Shift Valves and Shuttle Valve
1 ± SHUTTLE VALVE E-CLIP
2 ± SHUTTLE VALVE SECONDARY SPRING
3 ± SHUTTLE VALVE
4 ± 2±3 SHIFT VALVE
5 ± SHUTTLE VALVE PRIMARY SPRING
6 ± 2±3 SHIFT VALVE SPRING
7 ± SHUTTLE VALVE PLUG
8 ± SCREWS9 ± BY-PASS VALVE SPRING
10 ± 1±2 SHIFT VALVE SPRING
11 ± 1±2 SHIFT VALVE
1 2 ± B Y- PA S S VA LV E
13 ± TORQUE CONVERTER CLUTCH SOLENOID
14 ± VALVE BODY
15 ± SPRING GUIDES (2)
PLTRANSAXLE 21 - 103
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Transfer shaft
²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
STIRRUP AND STRAP INSTALLATION
Once bearing shim selection has been adjusted,
install stirrup and strap assembly onto transfer gear.
NOTE: Once the stirrup assembly is positioned
onto the transfer gear, it is necessary to ªclockº the
stirrup against the flats of the transfer gear retain-
ing nut.
(1) Position the stirrup on the transfer gear.
(2) Position strap.
(3) Install retaining bolts into transfer gear. Fin-
ger±tighten bolts.
(4) Turn stirrup clockwise against the flats of the
transfer gear retaining nut.
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.).(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
Fig. 155 Install Transfer Shaft Bearing Cup
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4520
4 ± TRANSFER SHAFT BEARING RETAINER
5 ± ªOº RING
Fig. 156 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 ± TRANSFER SHAFT GEAR
2 ± TORQUE WRENCH
3 ± SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 157 Checking Transfer Shaft End Play
1 ± SPECIAL TOOL L-4432 AND C-4658
2 ± TRANSFER SHAFT GEAR
3 ± STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 ± DIAL INDICATOR
5 ± SCREW (2)
21 - 120 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

PARKING PAWL
DISASSEMBLY
ASSEMBLY
To install, reverse the above procedure.
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
STIRRUP AND RETAINING STRAP
NOTE: A stirrup and retaining strap (Fig. 161) is
attached to the output gear. The stirrup prevents
the output gear retaining nut from turning and
backing off the output shaft. The strap is used to
hold the stirrup to the output gear and prevent the
stirrup retaining bolts from backing out.
REMOVAL
Fig. 158 Parking Sprag Rod Support
1 ± PARKING SPRAG ROD SUPPORT
2 ± BOLT (2)
3 ± OUTPUT SHAFT GEAR
Fig. 159 Support and Bolts
1 ± BOLT (2)
2 ± PARKING SPRAG ROD SUPPORT
Fig. 160 Parking Pawl, Return Spring, and Pivot
Shaft
1 ± PARKING PAWL
2 ± RETURN SPRING
3 ± NOTE: SMALL DIAMETER TO REAR
4 ± PIVOT SHAFT
Fig. 161 Stirrup and Retaining Strap Assembly
1 ± STRAP
2 ± RETAINING BOLTS (2)
3 ± OUTPUT GEAR
4 ± STIRRUP
PLTRANSAXLE 21 - 121
DISASSEMBLY AND ASSEMBLY (Continued)