lock DODGE NEON 2000 Service Repair Manual

(11) Disconnect the vehicle speed sensor connector
(Fig. 39).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 40).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 40).
(17) Remove bellhousing dust cover (Fig. 40).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 41).
(19) Remove starter motor (Fig. 42).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 43).
Fig. 39 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINION
Fig. 40 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 41 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
PLTRANSAXLE 21 - 15
REMOVAL AND INSTALLATION (Continued)

(11) Remove reverse idler gear and spacer (Fig.
53).
(12) Remove two screws retaining reverse fork
bracket (Fig. 54). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 55).(13) Using snap±ring pliers, remove selector shaft
spacer (Fig. 56).
(14) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 57).
Fig. 53 Reverse Idler Gear and Spacer Removal
1 ± SPACER
2 ± REVERSE IDLER GEAR
Fig. 54 Screws Retaining Reverse Fork Bracket
1 ± SCREWS (2)
2 ± REVERSE FORK BRACKET
Fig. 55 Remove Reverse Fork Bracket
1 ± REVERSE FORK BRACKET
2 ± REVERSE CAM BLOCKOUT
3 ± SHIFT BLOCKER ASSEMBLY
Fig. 56 Remove Selector Shaft Spacer
1 ± SHIFT BLOCKER ASSEMBLY
2 ± SELECTOR SHAFT SPACER (PLASTIC)
3 ± SNAP RING PLIERS
21 - 20 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(22)TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim,
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 66) (Fig. 67) (Fig. 68)
(Fig. 69) (Fig. 70).TRANSAXLE W/O REVERSE
BRAKE:Remove plastic spacer from the input shaft
assembly.
Fig. 65 Oil Feed Trough
1 ± OIL FEED TROUGH
Fig. 66 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 67 Reverse Brake Friction Cone
1 ± REVERSE BRAKE FRICTION CONE
Fig. 68 Reverse Brake Blocking Ring
1 ± REVERSE BRAKE BLOCKING RING
Fig. 69 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

(23) Remove the shift blocker assembly from the
bench fixture (Fig. 71).
(24) Remove the 1-2 shift fork from the output
shaft (Fig. 72).
(25) Remove input and output shaft assemblies
from bench fixture (Fig. 73).CAUTION: The output shaft assembly is serviced
as an assembly. Do not try to repair any component
on the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the complete output
shaft assembly.
Fig. 70 Reverse Brake Race
1 ± REVERSE BRAKE RACE
Fig. 71 Shift Blocker Removal
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 72 1±2 Shift Fork Removal
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 73 Gear Train Removal
1 ± 6785 BENCH FIXTURE
2 ± INPUT AND OUTPUT SHAFTS
21 - 24 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end plate cover is
MopartRTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 74).
(2) Install shift rails and forks into bench fixture
(Fig. 75).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 76).
(4) Install reverse brake race onto input shaft (Fig.
77).
(5) Install reverse brake needle bearing (Fig. 78).
Fig. 74 Bench Fixture
1 ± BENCH FIXTURE
2 ± GEARTRAIN
Fig. 75 Shift Rail Installation
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 76 Shift Blocker Installation
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 77 Reverse Brake Race Installation
1 ± REVERSE BRAKE RACE
Fig. 78 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(6) Install reverse brake blocking ring (Fig. 79).
(7) Install reverse brake friction cone (Fig. 80).(8) Install reverse brake shim (Fig. 81). Apply
petroleum jelly to shim to hold in place.
(9) Install gear±case half over bench fixture (Fig.
82). Line up shift finger over 3-4 lug.
Fig. 79 Reverse Brake Blocking Ring Installation
1 ± REVERSE BRAKE BLOCKING RING
Fig. 80 Reverse Brake Friction Cone Installation
1 ± REVERSE BRAKE FRICTION CONE
Fig. 81 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 82 Gear Case Half
1 ± TRANSAXLE CASE
2 ± BENCH FIXTURE
3 ± GEARTRAIN
21 - 26 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(14) Remove gear case from bench fixture.
(15) Install gear case in a holding fixture with end
cover facing down.
(16) Turn selector shaft into slot on blocker assem-
bly (Fig. 87).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers.
(18) Install reverse idler gear and spacer as shown
in (Fig. 88)(19) Install reverse idler shaft (Fig. 89).
(20) Install bolt into shaft and tighten to 26 N´m
(19 ft. lbs.) torque (Fig. 90).
Fig. 87 Selector Shaft
1 ± SHIFT ASSEMBLY
2 ± SELECTOR SHAFT
Fig. 88 Reverse Idler Gear and Spacer
1 ± SPACER
2 ± REVERSE IDLER GEAR
Fig. 89 Reverse Idler Shaft
1 ± REVERSE IDLER SHAFT
Fig. 90 Reverse Idler Shaft Bolt
1 ± CASE
2 ± REVERSE IDLER SHAFT
3 ± REVERSE IDLER SHAFT BOLT
21 - 28 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(21) Install reverse fork bracket and reverse lock-
out. Tighten screws to 11 N´m (96 in. lbs.) torque
(Fig. 91) (Fig. 92).(22) Install differential into gear case (Fig. 93).
BEARING ADJUSTMENT PROCEDURE
(1) Use 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 bear-
ing seat gives 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
the 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.
Fig. 91 Reverse Fork Bracket
1 ± REVERSE FORK BRACKET
2 ± REVERSE CAM BLOCKOUT
3 ± SHIFT BLOCKER ASSEMBLY
Fig. 92 Reverse Fork Screws
1 ± SCREWS (2)
2 ± REVERSE FORK BRACKET
Fig. 93 Differential Assembly
1 ± INPUT SHAFT
2 ± OUTPUT SHAFT
3 ± DIFFERENTIAL
4 ± CASE
PLTRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Remove 4th gear (Fig. 103).
(8) Remove 4th gear caged needle bearing (Fig.
104). Check the caged needle bearing for a broken
retention spring.(9) Remove blocking ring. Remove 3-4 synchronizer
hub retaining snap ring (Fig. 105).
(10) Install input shaft in shop press. Using bear-
ing splitter, remove 3-4 synchronizer and 3rd gear
(Fig. 106).
(11) Remove 3rd gear caged needle bearing (Fig.
107). Check the caged needle bearing for a broken
retention spring.
(12) Inspect the input shaft for worn or damaged
bearing races or chipped gear teeth. Replace as nec-
essary.
Fig. 103 4th Gear Removal
1 ± INPUT SHAFT
2 ± 4TH GEAR
Fig. 104 Caged Needle Bearing Removal
1 ± INPUT SHAFT
2 ± CAGED NEEDLE BEARING
Fig. 105 3-4 Synchronizer Hub Snap Ring
1 ± SNAP RING PLIERS
2 ± SYNCHRO SNAP RING
3 ± SYNCHRONIZER ASSEMBLY
Fig. 106 3rd Gear Removal
1 ± PRESS RAM
2 ± INPUT SHAFT
3 ± 3RD GEAR
4 ± SYNCHRONIZER ASSEMBLY
PLTRANSAXLE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
The snap rings that are used on the input shaft
are available in select fit sizes. Use the thickest snap
ring that fits in each snap ring groove.
(1) Place input shaft into shop press.
(2) Install 3rd gear caged needle bearing on input
shaft.
(3) Install 3rd gear and 3-4 synchronizer onto
input shaft. Install Tool #C-3717 over input shaft and
press on synchronizer hub and 3rd gear (Fig. 108).
The synchronizer hub has the letterUstamped on
the top face of the hub. This designates that the hub
must be installed with theUfacing upward.(4) Install 3-4 synchronizer snap ring into slot on
input shaft.
(5) Install blocking ring into 3-4 synchronizer.
Install 4th gear caged needle bearing.
(6) Install 4th gear onto input shaft.
(7) Install 4-5 split thrust washer separation pin
(Fig. 109).
(8) Install split thrust washer onto input shaft
(Fig. 110).
Fig. 107 3rd Gear Caged Needle Bearing
1 ± INPUT SHAFT
2 ± 3RD GEAR CAGED NEEDLE BEARING
Fig. 108 Press On 3rd Gear Synchronizer Hub
1 ± PRESS RAM
2 ± SPECIAL TOOL C-3717
3 ± BEARING SPLITTER
4 ± 3RD GEAR SYNCHRONIZER ASSEMBLY
Fig. 109 Split Thrust Washer Separation Pin
Installation
1 ± SEPARATION PIN
2 ± INPUT SHAFT
3 ± PLIERS
Fig. 110 Split Thrust Washer Installation
1 ± INPUT SHAFT
2 ± SPLIT THRUST WASHER
21 - 34 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)