torque DODGE NEON 2000 Service Repair Manual

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearing turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 178 Install Output Shaft into Rear Planetary
Annulus Gear
1 ± PRESS
2 ± 1/2 INCH SOCKET
3 ± OUTPUT SHAFT
4 ± REAR ANNULUS GEAR
5 ± SPACER
Fig. 179 Install Output Shaft Gear Bearing Cup
1 ± OUTPUT SHAFT GEAR BEARING CUP
2 ± SPECIAL TOOL L-4429-3
Fig. 180 Install Rear Planetary Annulus Gear
Bearing Cup
1 ± SPECIAL TOOL L-4429-3
Fig. 181 Install Output Shaft Assembly
1 ± OUTPUT SHAFT ASSEMBLY
2 ± USE GREASE TO HOLD SHIMS IN POSITION
3 ± BEARING CONE
4 ± LUBRICATION HOLE
5 ± SELECT SHIMS
21 - 126 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

STIRRUP AND RETAINING STRAP
INSTALLATION
Once bearing turning torque and shim selection
has been adjusted, install stirrup and strap assembly
onto output gear.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.
(1) Position the stirrup on the output gear.
(2) Position strap.
(3) Install retaining bolts into output gear. Finger±
tighten bolts.
(4) Turn stirrup clockwise against the flats of the
output gear retaining nut (Fig. 188).
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.)
(Fig. 189).
(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
Fig. 187 Checking Bearing Turning Torque
1 ± OUTPUT SHAFT GEAR
2 ± TORQUE WRENCHFig. 188 Turn Stirrup Clockwise Against Flats Of
Retaining Nut
1 ± TURN STIRRUP CLOCKWISE
2 ± STRAP
Fig. 189 Tighten Strap Retaining Nuts
1 ± STRAP
2 ± OUTPUT GEAR
3 ± STIRRUP
21 - 128 TRANSAXLEPL
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)

(d) Tighten shift cable adjustment screw to 8
N´m (70 in. lbs.) torque.
(4) Verify proper cable adjustment. Engine should
start with the shifter lever in PARK (P) and NEU-
TRAL (N) positions ONLY.
(5) Install center console assembly (Fig. 215).
(6) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 214).
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.
(1) Verify cable is routed properly with no kinked
or binding conditions.(2) Release adjustment locking clip on cable at
throttle body.It is not necessary to remove clip.
(3) Grab cable conduit near adjustment body, push
in towards throttle body, then release grip (Fig. 217).
This allows cable to self adjust.
(4) Press locking clip to secure cable position (Fig.
218).
(5) Road test vehicle to verify proper transaxle
operation.
Fig. 216 Gearshift Cable Adjustment Screw
1 ± GEARSHIFT CABLE ADJUSTMENT SCREW
Fig. 217 Throttle Valve Cable Adjustment
1 ± TAB UNLOCKED
Fig. 218 Cable Locking Clip
1 ± TAB LOCKED
2 ± THROTTLE VALVE CABLE
21 - 136 TRANSAXLEPL
ADJUSTMENTS (Continued)

BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
VERIFICATION
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.
ADJUSTMENT
(1) Loosen set screw and remove knob from shifter
handle (Fig. 219).
(2) Remove the center console assembly as shown
in (Fig. 220).
(3) Remove shifter bezel (Fig. 221).
(4)Adjust interlock cable/system as follows:
Pry up on cable adjuster lock to release and allow
cable to ªself-adjustº. Lock cable adjustment by press-
ing down on the adjuster lock until bottomed at the
cable housing.
(5) Verify correct system operation. Refer to verifi-
cation procedure.
(6) Install shifter bezel (Fig. 221).
(7) Install center console assembly (Fig. 220).
(8) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 219).
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. 219 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 220 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
PLTRANSAXLE 21 - 137
ADJUSTMENTS (Continued)

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)

OUTPUT SHAFT BEARING
With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shim on the planetary rear annulus gear hub using
grease to hold the shim in place. The 13.65 mm shim
has a larger inside diameter and must be installed
over the output shaft first. The 1.34 mm shim pilots
on the output shaft.
Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
To measure bearing end play:
(1) Attach Tool L-4432 to the output shaft gear.
(2) Mount a steel ball with grease into the end of
the output shaft.
(3) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(4) Using a dial indicator mounted to the transaxle
case, measure output shaft end play.
(5) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(6) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
that are necessary for proper bearing lubrica-
tion.
(7) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(8) Use tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use tool
L-4407.
(9) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.
(10) Install the retaining nut and washer, and
torque to 271 N´m (200 ft. lbs.).
(11) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(12) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
DIFFERENTIAL BEARING
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft.
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential.
OUTPUT SHAFT BEARING SHIM CHART
Fig. 222 Tool L-4436 and Torque Wrench
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
3 ± DIFFERENTIAL BEARING RETAINER
PLTRANSAXLE 21 - 139
ADJUSTMENTS (Continued)

The turning torque should be between 5 and 18
inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e)
NOTE: If the turning torque was too high when
measured, install a.05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a.05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differen-
tial.The turning torque should be between 5
and 18 inch-pounds.
TRANSFER SHAFT BEARING
(1) Use tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
a. Attach tool L-4432 to the transfer gear.
b. Mount a steel ball with grease into the end of
the transfer shaft.
c. Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
d. Using a dial indicator, measure transfer shaft
end play.
e. Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
f. Use tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using tool
L-4407.
Fig. 223 Checking Differential Bearings Turning
Torque
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
21 - 140 TRANSAXLEPL
ADJUSTMENTS (Continued)

g. Remove the two gauging shims and install the
correct shim combination. Install the transfer gear
and bearing assembly.
h. Install the retaining nut and washer and torque
to 271 N´m (200 ft. lbs.). Measure transfer shaft end
play, end play should be 0.05 to 0.25 mm (0.002 to
0.010 inch).
i. Measure bearing end play. End play should be
between.05 mm and.25 mm (.002 to.010 inch).
NOTE: If end play is too high, install a 0.05 mm
(0.002 inch) thinner shim combination. If end play is
too low, install a 0.05 mm (0.002 inch) thicker shim
combination. Repeat until 0.05 to 0.25 mm (0.002 to
0.010 inch) end play is obtained.TRANSFER BEARING SHIM CHART
PLTRANSAXLE 21 - 141
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