center console DODGE NEON 2000 Service Owner's Manual

Connector
Name/NumberColor Location Fig.
Left License
Lamp
(Built-Up-
Export)NAT Rear of Lamp 13
Left Park/Turn
Signal Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Left Rear Door
Lock MotorBK At Motor 16
Left Rear Fog
Lamp
(Built-Up-
Export)GY At Lamp N/S
Left Rear
SpeakerBK At Speaker 11
Left Rear Turn
Signal Lamp
(Built-Up-
Export)GY At Lamp 11
Left Rear
Wheel Speed
SensorBL At Left Rear
Wheel
OpeningN/S
Left Repeater
Lamp
(Built-Up-
Export)BL At Lamp 1
Left Tail/Stop
Lamp
(Built-Up-
Export)BK At Lamp 11
Left Tail/Stop/
Turn Signal
Lamp (Except
Built-Up-
Export)BK At Lamp N/S
License Lamp
(Except
Built-Up-
Export)NAT Rear of Lamp N/S
Low Note
HornBK Right Inner
Fender1
Manifold
Absolute
Pressure
SensorBK Left Front of
Engine4
Map/Reading
LampsBK Front of
Headliner9Connector
Name/NumberColor Location Fig.
Multi-Function
SwitchGY Left Side of
Instrument
Panel6
Oxygen
Sensor 1/1
UpstreamGY Right Rear of
Engine5
Oxygen
Sensor 1/2
Downstream
(2.0L)GY Right Rear of
Engine5
Park/Neutral
Position
Switch (ATX)BK On
TransmissionN/S
Passenger
AirbagYL Right Side of
Instrument
Panel6
Passenger
Cylinder Lock
SwitchBK At
Passengers
Door15
Passenger
Door Lock
MotorBK At
Passengers
Door15
Passenger
Door Lock
SwitchBK At
Passengers
Door15
Passenger
Power MirrorGY At
Passengers
Door15
Passenger
Power
Window MotorBK At
Passengers
Door15
Passenger
Power
Window
SwitchGY At
Passengers
Door15
Power Mirror
SwitchGY At Drivers
Door14
Power
Steering
Pressure
SwitchGY Left Rear of
Engine
Compartment2
Powertrain
Control
Module - C1BK Left Fender
Side Shield4
Powertrain
Control
Module - C2BK Left Fender
Side Shield2
PRNDL Lamp BK At Center
Console6
8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Oxygen
Sensor 1/2
Downstream
(2.0L)GY Right Rear of
Engine22
Park/Neutral
Position
Switch (ATX)BK On
TransmissionN/S
Passenger
AirbagYL Left Side of
Instrument
Panel25
Passenger
Cylinder Lock
SwitchBK At
Passengers
Door33
Passenger
Door Lock
MotorBK At
Passengers
Door33
Passenger
Door Lock
SwitchBK At
Passengers
Door33
Passenger
Power MirrorBL At
Passengers
Door33
Passenger
Power
Window MotorBK At
Passengers
Door33
Passenger
Power
Window
SwitchGY At
Passengers
Door33
Power Mirror
SwitchGY At Drivers
Door34
Power
Steering
Pressure
SwitchGY Left Rear of
Engine
CompartmentN/S
Powertrain
Control
Module - C1BK Left Fender
Side Shield21
Powertrain
Control
Module - C2BK Left Fender
Side Shield19
PRNDL Lamp BK At Center
Console25
Proportional
EVAP/Purge
SolenoidBK Left Rear of
Engine
Compartment19
Radiator Fan
MotorBK Front of
Engine
Compartment19Connector
Name/NumberColor Location Fig.
Radio - C1 BK Rear of Radio 24
Radio - C2 GY Rear of Radio 24
Rear Window
Defogger
SwitchBK Center of
Instrument
Panel24
Remote
Keyless Entry
ModuleBK Center of
Instrument
Panel24
Right Back-Up
LampBK At Lamp 31
Right City
LampGY At Lamp N/S
Right Front
Door SpeakerBK At Drivers
Door34
Right Front
Fog LampBK At Lamp N/S
Right Front
Turn Signal
LampNAT At Lamp 20
Right Front
Wheel Speed
SensorBK At Right Front
Wheel
Opening20
Right
HeadlampBK At Lamp 20
Right
Headlamp
Leveling MotorGY Rear of right
HeadlampN/S
Right
Instrument
Panel SpeakerBK At Speaker 25
Right License
LampNAT At Lamp 32
Right Rear
Door Lock
MotorBK At Motor 35
Right Rear
Fog LampGY At Lamp 32
Right Rear
SpeakerBK At Speaker 30
Right Rear
Turn Signal
LampGY At Lamp 31
Right Rear
Wheel Speed
SensorBL At Right Rear
Wheel
OpeningN/S
Right
Repeater
LampBL At Lamp 18
8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

INSTALLATION
(1) Install knob to shifter lever, align knob to three
o'clock position, push knob down to engage spring
and rotate counter clockwise (Fig. 6).
(2) Return shifter boot to its original position
(seated around knob lip).
GEARSHIFT BOOT
REMOVAL
(1) Pull shifter boot down and away from shifter
knob.
(2) Push down on knob and rotate clockwise to
remove (Fig. 7).
(3) Remove the center console assembly as shown
in (Fig. 8).(4) Separate shifter boot from shifter assembly
(Fig. 9). Boot is retained to shifter by three push-pin
retainers.
INSTALLATION
(1) Install boot to the shifter assembly (Fig. 9).
Fasten boot to shifter with the three retainers.
(2) Install center console assembly (Fig. 8). Verify
that boot is not pinched at console opening before
tightening.
(3) Install knob to shifter lever, align knob to three
o'clock position, push knob down to engage spring
and rotate counter clockwise (Fig. 10).
Fig. 6 Gearshift Knob Installation
1 ± GEARSHIFT KNOB
2 ± SPRING
Fig. 7 Gearshift Knob Removal
1 ± GEARSHIFT KNOB
Fig. 8 Center Console Removal/InstallationÐTypical
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 9 Gearshift Boot Removal/Installation
1 ± BOOT
2 ± SHIFTER ASSEMBLY
PLTRANSAXLE 21 - 5
REMOVAL AND INSTALLATION (Continued)

(4) Return shifter boot to its original position
(seated around knob lip).
GEARSHIFT CABLE ASSEMBLY
NOTE: The crossover and selector cables are man-
ufactured as a cable ªassemblyº and cannot be ser-
viced individually.
REMOVAL
(1) Raise hood and disconnect battery negative
cable.
(2) Pull shifter boot down and away from shifter
knob.
(3) Push down on knob and rotate clockwise to
remove (Fig. 11).
(4) Remove the center console assembly as shown
in (Fig. 12).
(5) Separate shifter boot from shifter assembly
(Fig. 13). Boot is retained to shifter by three push-pin
retainers.
(6) Remove crossover cable retaining clip and dis-
connect from shift lever (Fig. 14).
(7) Remove selector cable retaining clip and dis-
connect from shift lever (Fig. 15).
(8) Remove three grommet plate-to-floor pan
attaching nuts (Fig. 14).
(9) Remove air cleaner/throttle body assy. (Fig. 16)
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) Disconnect throttle body air duct from intake
manifold.
(d) Remove mounting bolt and nut (Fig. 16) and
partially remove air cleaner assembly.
(e) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(10) Disconnect cables from the shift levers at the
transaxle (Fig. 17).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 10 Gearshift Knob Installation
1 ± GEARSHIFT KNOB
2 ± SPRING
Fig. 11 Gearshift Knob Removal
1 ± GEARSHIFT KNOB
Fig. 12 Center Console Removal/InstallationÐ
Typical
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
21 - 6 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(6) Install gearshift cables to mounting bracket
and fasten with NEW clips (Fig. 17). Make sure clips
are installed flush to bracket.
(7) Connect gearshift selector and crossover cable
to shift levers at transaxle (Fig. 17).
(8) Install and tighten the three grommet plate-to-
floor pan nuts to 6 N´m (50 in. lbs.) torque.
(9) Install selector cable to shifter lever and secure
cable to shifter bracket. Install clip (Fig. 15).
(10) Install crossover cable to shifter lever and
secure cable to shifter bracket. Install clip (Fig. 14).NOTE: Only the crossover cable is adjustable. The
selector cable does not have any adjustment capa-
bilities.
(11)Adjust crossover cable as follows:
(a) Loosen adjusting screw on crossover cable at
shifter (Fig. 20).
(b) Pin transaxle crossover lever in 3-4-N posi-
tion using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the
transaxle case (Fig. 21). Be sure drill bit goes into
transaxle case at least one half inch.
(c) The shifter is spring±loaded and self±center-
ing. Allow shifter to rest in its neutral position.
Torque adjustment screw to 8 N´m (70 in. lbs.).
Care must be taken to avoid moving the shift
mechanism off-center during screw tightening.
(d) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(12) Install boot to the shifter assembly (Fig. 13).
Fasten boot with the three retainers.
(13) Install center console assembly (Fig. 12). Ver-
ify that boot is not pinched at console opening before
tightening.
(14) Install knob to shifter lever, align knob to
three o'clock position, push knob down to engage
spring and rotate counter clockwise (Fig. 22).
(15) Return shifter boot to its original position
(seated around knob lip).
(16) Install the air cleaner/throttle body assy. (Fig.
16) as follows:
Fig. 17 Shift Cables at Transaxle
1 ± SHIFT CABLES
2 ± CLIPS
3 ± BRACKET
Fig. 18 Converter Heat Shield Removal/Installation
1 ± CONVERTER HEAT SHIELD
Fig. 19 Shift Cable Assembly at Floor Pan
1 ± CABLE ASSEMBLY
2 ± GROMMET PLATE
21 - 8 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(3) Remove the center console assembly as shown
in (Fig. 24).
(4) Separate shifter boot from shifter assembly
(Fig. 25). Boot is retained to shifter by three push-pin
retainers.
(5) Remove crossover cable retaining clip and dis-
connect from shift lever (Fig. 26).
(6) Remove selector cable retaining clip and dis-
connect from shift lever (Fig. 27).
(7) Remove four shifter assy.-to-floor pan nuts and
remove shifter from vehicle (Fig. 28).
INSTALLATION
(1) Install shifter assy. to floor pan (Fig. 28).
Install and tighten four nuts to 12 N´m (105 in. lbs.)
torque.
(2) Install selector cable to shifter lever and secure
cable to shifter bracket. Install clip (Fig. 27).
(3) Install crossover cable to shifter lever and
secure cable to shifter bracket. Install clip (Fig. 26).
(4) Install boot to the shifter assembly (Fig. 25).
Fasten boot with the three retainers.
Fig. 24 Center Console Removal/InstallationÐ
Typical
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 25 Gearshift Boot Removal/Installation
1 ± BOOT
2 ± SHIFTER ASSEMBLY
Fig. 26 Crossover Cable at Shifter Assembly
1 ± GROMMET PLATE NUT
2 ± SHIFTER
3 ± CROSSOVER CABLE
4 ± CLIP
Fig. 27 Selector Cable at Shifter Assembly
1 ± SHIFTER
2 ± CLIP
3 ± SELECTOR CABLE
21 - 10 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(5) Install center console assembly (Fig. 24). Verify
that boot is not pinched at console opening before
tightening.
(6) Install knob to shifter lever, align knob to three
o'clock position, push knob down to engage spring
and rotate counter clockwise (Fig. 29).
(7) Return shifter boot to its original position
(seated around knob lip).
VEHICLE SPEED SENSOR AND DRIVE PINION
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the speed sensor connector (Fig.
30).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.
(3) Remove speed sensor retaining bolt (Fig. 30).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into tran-
saxle. Should sensor drive gear fall into the tran-
saxle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
Fig. 28 Shifter Assy. Removal/Installation
1 ± SHIFTER ASSEMBLY
Fig. 29 Gearshift Knob Installation
1 ± GEARSHIFT KNOB
2 ± SPRING
Fig. 30 Speed Sensor and PinionÐRemoval/
Installation
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINION
PLTRANSAXLE 21 - 11
REMOVAL AND INSTALLATION (Continued)

ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
(1) Pull shifter boot down and away from shifter
knob.
(2) Push down on knob and rotate clockwise to
remove (Fig. 157).
(3) Remove the center console assembly as shown
in (Fig. 158).
(4) Separate shifter boot from shifter assembly
(Fig. 159). Boot is retained to shifter by three push-
pin retainers.(5) Loosen crossover adjustment screw at shifter
assembly (Fig. 160).
(6) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 161). Be sure drill bit goes into transaxle
case at least one±half inch.
(7) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(8) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(9) Install boot to the shifter assembly (Fig. 159).
Fasten boot with the three retainers.
Fig. 157 Gearshift Knob Removal
1 ± GEARSHIFT KNOB
Fig. 158 Center Console Removal/InstallationÐ
Typical
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 159 Gearshift Boot Removal/Installation
1 ± BOOT
2 ± SHIFTER ASSEMBLY
Fig. 160 Crossover Adjustment Screw
1 ± CROSSOVER ADJUSTMENT SCREW
PLTRANSAXLE 21 - 49

(10) Install center console assembly (Fig. 158). Ver-
ify that boot is not pinched at console opening before
tightening.
(11) Install knob to shifter lever, align knob to
three o'clock position, push knob down to engage
spring and rotate counter clockwise (Fig. 162).
(12) Return shifter boot to its original position
(seated around knob lip).
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor pressfor installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings, if one input shaft bearing is defective, replace
both input shaft bearings.
(5) Bearing cones must not be reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction.
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT
NOTE: True bearing turning torque readings can be
obtained only with the geartrain removed from the
case.
(1) Remove bearing cup and existing shim from
clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Moparttype M.
S. 9417 Manual Transaxle Fluid. Install differential
assembly in transaxle gear case. Install clutch bell-
housing over gear case. Install and torque case bolts
to 29 N´m (21 ft. lbs.).
(5)
Position transaxle with bellhousing facing down
on workbench with C-clamps. Position dial indicator.
(6) Apply a medium load to differential with Tool
C-4995 and a T-handle, in the downward direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
indicator. To obtain end play readings, apply a
medium load in an upward direction while rolling
differential assembly back and forth (Fig. 163).
Record end play.
(7) The shim required for proper bearing preload is
thetotal of end play, plus (constant) preload of
0.18mm (0.007 in.).Never combine shims to obtain
the required preload.
Fig. 161 Crossover Lever Pin Procedure
1±1¤488DRILL BIT
2 ± SELECTOR CABLE
3 ± CROSSOVER CABLE
Fig. 162 Gearshift Knob Installation
1 ± GEARSHIFT KNOB
2 ± SPRING
21 - 50 TRANSAXLEPL
ADJUSTMENTS (Continued)

REMOVAL AND INSTALLATION
GEARSHIFT CABLE
REMOVAL
(1) Loosen set screw and remove knob from shifter
handle (Fig. 9).
(2) Remove the center console assembly as shown
in (Fig. 10).(3) Remove shifter bezel (Fig. 11).
(4) Disconnect shift cable from shifter assembly as
shown in (Fig. 12).
(5) Remove three grommet plate to floor pan nuts
as shown in (Fig. 12).
Fig. 9 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 10 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 11 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 12 Gearshift Cable at Shifter Assembly
1 ± SHIFTER ASSEMBLY
2 ± GROMMET PLATE NUT
3 ± SHIFT CABLE
PLTRANSAXLE 21 - 73