automatic transmission DODGE NEON 2000 Service Owner's Guide

(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALTERNATIVE MAINTENANCE METHODS
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION: The use of any fluid exchanger that
introduces additives into the transaxle is not rec-
ommended.
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating tempera-
ture.
(2) Obtain a suitable transaxle fluid exchanger
and verify the tank is clean and dry.
(3) Fill the tank to the recommended fill capacity
with MopartATF+4 Type 9602.
(4) Connect the machine to the vehicle following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with MopartATF+4 Type 9602. Refer
to Fluid Level and Condition Check in this group for
the proper fluid ªtop-offº procedure.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N²m (18 in. lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils. This repair consists of drilling out the
worn-out or damaged threads. Then tap the hole with
a Heli-Coil tap, and install a Heli-Coil insert into the
hole. This brings the hole back to its original thread
size.
Heli-Coil tools and inserts are readily available
from most automotive parts suppliers.
Fig. 8 Dipstick Markings
1 ± TRANSAXLE DIPSTICK
PLTRANSAXLE 21 - 71
SERVICE PROCEDURES (Continued)

FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the transaxle oil cooler(s) must be flushed (both
radiator and remote). The cooler bypass valve in the
transaxle must be replaced also. The torque con-
verter must also be replaced with an exchange unit.
This will ensure that metal particles or sludged oil
are not later transferred back into the reconditioned
(or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIT CIGARETTES, SPARKS, FLAMES, AND
OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readingsand clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
Fluid) Type 9602.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with MopartATF+4
(Automatic Transmission Fluid) Type 9602. The vol-
ume should be checked using the following proce-
dure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using MopartATF+4 (Automatic Trans-
mission Fluid) Type 9602.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
21 - 72 TRANSAXLEPL
SERVICE PROCEDURES (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

from memory after 40 consecutive warm-up cycles
without test failure.
Enabling ConditionsÐThe following conditions
must typically be met for the PCM to run the oxygen
sensor monitor:
²Battery voltage
²Engine temperature
²Engine run time
²Engine run time at a predetermined speed
²Engine run time at a predetermined speed and
throttle opening
²Transmission in gear (automatic only)
²Fuel system in Closed Loop
²Long Term Adaptive (within parameters)
²Power Steering Switch in low PSI (no load)
²Engine at idle
²Fuel level above 15%
²Ambient air temperature
²Barometric pressure
²Engine RPM within acceptable range of desired
idle
²Closed throttle speed
Pending ConditionsÐThe Task Manager typi-
cally does not run the Oxygen Sensor Monitor if over-
lapping monitors are running or the MIL is
illuminated for any of the following:
²Misfire Monitor
²Front Oxygen Sensor and Heater Monitor
²MAP Sensor
²Vehicle Speed Sensor
²Engine Coolant Temperature Sensor
²Throttle Position Sensor
²Engine Controller Self Test Faults
²Cam or Crank Sensor
²Injector and Coil
²Idle Air Control Motor
²EVAP Electrical
²EGR Solenoid Electrical
²Intake Air Temperature
²5 Volt Feed
ConflictÐThe Task Manager does not run the
Oxygen Sensor Monitor if any of the following condi-
tions are present:
²A/C ON (A/C clutch cycling temporarily sus-
pends monitor)
²Purge flow in progress
SuspendÐThe Task Manager suspends maturing
a fault for the Oxygen Sensor Monitor if an of the fol-
lowing are present:
²Oxygen Sensor Heater Monitor, Priority 1
²Misfire Monitor, Priority 2
OXYGEN SENSOR HEATER MONITOR
DESCRIPTIONÐIf there is an oxygen sensor
(O2S) DTC as well as a O2S heater DTC, the O2S
fault MUST be repaired first. After the O2S fault isrepaired, verify that the heater circuit is operating
correctly.
The voltage readings taken from the O2S are very
temperature sensitive. The readings are not accurate
below 300ÉC. Heating of the O2S is done to allow the
engine controller to shift to closed loop control as
soon as possible. The heating element used to heat
the O2S must be tested to ensure that it is heating
the sensor properly.
The heater element itself is not tested. The sensor
output is used to test the heater by isolating the
effect of the heater element on the O2S output volt-
age from the other effects. The resistance is normally
between 100 ohms and 4.5 megaohms. When oxygen
sensor temperature increases, the resistance in the
internal circuit decreases. The PCM sends a 5 volts
biased signal through the oxygen sensors to ground
this monitoring circuit. As the temperature increases,
resistance decreases and the PCM detects a lower
voltage at the reference signal. Inversely, as the tem-
perature decreases, the resistance increases and the
PCM detects a higher voltage at the reference signal.
an The O2S circuit is monitored for a drop in voltage.
OPERATIONÐThe Oxygen Sensor Heater Moni-
tor begins after the ignition has been turned OFF
and the O2 sensors have cooled. The PCM sends a 5
volt bias to the oxygen sensor every 1.6 seconds. The
PCM keeps it biased for 35 ms each time. As the sen-
sor cools down, the resistance increases and the PCM
reads the increase in voltage. Once voltage has
increased to a predetermined amount, higher than
when the test started, the oxygen sensor is cool
enough to test heater operation.
When the oxygen sensor is cool enough, the PCM
energizes the ASD relay. Voltage to the O2 sensor
begins to increase the temperature. As the sensor
temperature increases, the internal resistance
decreases. The PCM continues biasing the 5 volt sig-
nal to the sensor. Each time the signal is biased, the
PCM reads a voltage decrease. When the PCM
detects a voltage decrease of a predetermined value
for several biased pulses, the test passes.
The heater elements are tested each time the
engine is turned OFF if all the enabling conditions
are met. If the monitor fails, the PCM stores a
maturing fault and a Freeze Frame is entered. If two
consecutive tests fail, a DTC is stored. Because the
ignition is OFF, the MIL is illuminated at the begin-
ning of the next key cycle.
Enabling ConditionsÐThe following conditions
must be met for the PCM to run the oxygen sensor
heater test:
²Engine run time of at least 5.1 minutes
²Key OFF power down
²Battery voltage of at least 10 volts
²Sufficient Oxygen Sensor cool down
PLEMISSION CONTROL SYSTEMS 25 - 21
DESCRIPTION AND OPERATION (Continued)

VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Passenger Safety E = Active Restraints, Driver and Passenger Airbags
5 Car Line S = Neon BUX L. H. D.
V = Neon BUX R. H. D.
6 Series M = DD5 5-Speed Manual Transmission
A = 3-Speed Automatic Transmission
7 Body Style7 = 4 Door Pillared Hardtop
8 Engine C = 2.0L 4 Cyl. 16V SOHC
A = 1.8L 4 Cyl. 16V SOHC
9 Check Digit See explanation in this section.
10 Model Year Y = 2000
11 Assembly Plant D = Belvedere Assembly
12 Thru 17 Build Sequence 6 Digit number assigned by assembly plant
E-MARK LABEL
An E-mark Label (Fig. 3) is located on the rear
shut face of the driver's door. The label contains the
following information:
²Date of Manufacture
²Month-Day-Hour (MDH)
²Vehicle Identification Number (VIN)
²Country Codes
²Regulation Number
²Regulation Amendment Number
²Approval Number
Fig. 3 E-Mark Label
1 ± Country Code
2 ± Regulation Number
3 ± Approval Number
4 ± Amendment Number
2 INTRODUCTIONPL
GENERAL INFORMATION (Continued)