lock DODGE NEON 2000 Service Repair Manual

(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi.as lever is moved counter-
clockwise.
(6) Low/reverse pressure should read the same as
line pressure, within 3 psi.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and rear servo hydraulic
circuits.
Fig. 5 Test Port Locations
1 ± ACCUMULATOR VENT
2 ± MANUAL THROTTLE LEVER SHAFT
3 ± MANUAL SHIFT LEVER SHAFT
4 ± LOW-REVERSE PRESSURE
5 ± GOVERNER PRESSURE (BELOW DIFFERENTIAL COVER
ON RIGHT SIDE)
6 ± LINE PRESSURE
7 ± KICKDOWN APPLY AT ACCUMULATOR8 ± TO COOLER
9 ± KICKDOWN RELEASE (FRONT CLUTCH)
10 ± KICKDOWN APPLY
11 ± CONVERTER CLUTCH SOLENOID CONNECTOR
12 ± FROM COOLER
13 ± KICKDOWN BAND ADJUSTING SCREW
Fig. 6 Governor Pressure Tap
1 ± GOVERNOR PRESSURE PLUG
PLTRANSAXLE 21 - 67
DIAGNOSIS AND TESTING (Continued)

TEST TWO (SELECTOR IN 2)
(1) Attach one gauge to line pressure port, and tee
another gauge into lower cooler line fitting. This will
allow lubrication pressure readings to be taken..
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle one detent for-
ward from full rearward position. This is selector 2
position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Lubrication pressure should be 10 to 25 psi
with lever clockwise and 10 to 35 psi with lever at
full counterclockwise.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and lubrication hydraulic
circuits.
TEST THREE (SELECTOR IN D)
(1) Attach gauges to line and kickdown release
ports.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle two detents
forward from full rearward position. This is selector
D position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise to the full
counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Kickdown release is pressurized only in direct
drive and should be same as line pressure within 3
psi, up to kickdown point.
(7) This tests pump output, pressure regulation,
and condition of rear clutch, front clutch, and
hydraulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to low-reverse port.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle four detents
forward from full rearward position. This is selector
R position.
(4) Low/reverse pressure should read 180 to 220
psi with throttle lever clockwise. Pressure should
gradually increase to 260 to 300 psi. as lever is
moved counterclockwise.
(5) This tests pump output, pressure regulation,
and condition of front clutch and rear servo hydraulic
circuits.(6) Move selector lever on transaxle to D position
to check that low/reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to
case porosity, which can cause reverse band burn out.
TEST RESULT INDICATIONS
(1) If proper line pressure, minimum to maximum,
is found in any one test, the pump and pressure reg-
ulator are working properly.
(2) Low pressure in D, 1, and 2 but correct pres-
sure in R, indicates rear clutch circuit leakage.
(3) Low pressure in D and R, but correct pressure
in 1 indicates front clutch circuit leakage.
(4) Low pressure in R and 1, but correct pressure
in 2 indicates rear servo circuit leakage.
(5) Low line pressure in all positions indicates a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GOVERNOR PRESSURE
Test only if transaxle shifts at wrong vehicle
speeds when throttle cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off point. It is located at lower right
side of case, below differential cover.
(2) Operate transaxle in third gear to read pres-
sures. The governor pressure should respond
smoothly to changes in mph and should return to 0
to 3 psi when vehicle is stopped. High pressure
(above 3 psi) at standstill will prevent the transaxle
from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure.
Incorrect throttle pressure should be suspected if
part throttle upshift speeds are either delayed or
occur too early in relation to vehicle speed. Engine
runaway on shifts can also be an indicator of low
throttle pressure setting, or misadjusted throttle
cable.
In no case should throttle pressure be adjusted
until the transaxle throttle cable adjustment has
been verified to be correct.
CLUTCH AND SERVO AIR PRESSURE TESTS
A no±drive condition might exist even with correct
fluid pressure, because of inoperative clutches or
bands. The inoperative units, clutches, bands, and
servos can be located through a series of tests. This
is done by substituting air pressure for fluid pressure
(Fig. 7).
The front and rear clutches, kickdown servo, and
low/reverse servo can be tested by applying air pres-
sure to their respective passages. To make air pres-
sure tests, proceed as follows:
21 - 68 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

LOW AND REVERSE SERVO (REAR)
Direct air pressure into LOW/REVERSE SERVO
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
ton should release the band.
If clutches and servos operate properly, no upshift
indicates that a malfunction exists in the valve body.
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA
(1) Check for source of leakage.
(2) Since fluid leakage near the torque converter
area may be from an engine oil leak, the area should
be checked closely. Factory fill fluid is dyed red and,
therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
vent in the dipstick. If the fluid level is high, adjust
to proper level.
(6) After performing this operation, inspect for
leakage. If a leak persists, perform the following
operation on the vehicle. This will determine if the
torque converter or transaxle is leaking.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter (peripheral) weld
²Torque converter hub weld
²Torque converter impeller shell cracked adjacent
to hub
²At drive lug welds
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
BRAKE TRANSMISSION SHIFT INTERLOCK
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. Refer to Brake Transmission Interlock
Removal and Installation or Adjustment in this
Group.
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE
NOTE: Refer to Group 0, Lubrication and Mainte-
nance, or the vehicle owner's manual, for the rec-
ommended maintenance (fluid/filter change)
intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparT
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist (See Lubrication,
Group 0). Place a drain container with a large open-
ing, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body and tighten retaining screws to 5 N´m (40
in. lbs.).
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.
21 - 70 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

(6) Disconnect the shifter/ignition interlock cable
from the shifter lever and bracket as shown in (Fig.
22).
(7) Remove the four shifter assembly-to-floor pan
nuts and remove shifter assembly from vehicle (Fig.
23).INSTALLATION
(1) Install gearshift mechanism and tighten the
four nuts to 12 N´m (105 in. lbs.) torque.
(2) Install gearshift cable as shown in (Fig. 21).
(3) Install shifter/ignition interlock cable as shown
in (Fig. 22).
(4) Install shifter bezel (Fig. 20).
(5) Install center console assembly (Fig. 19).
(6) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 18).
THROTTLE VALVE (KICKDOWN) CABLE
REMOVAL
(1) Remove air cleaner/throttle body assy. (Fig. 24)
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 at intake
manifold.
(d) Remove mounting bolt and nut (Fig. 24) and
partially remove air cleaner assembly (leave cables
attached).
NOTE: Pay attention to throttle valve cable routing
before removal so it can be re-installed in the same
manner. For proper transaxle operation, the cable
must not bind.
Fig. 22 Shifter Ignition Interlock Cable
1 ± INTERLOCK CABLE
2 ± SHIFTER ASSEMBLY
Fig. 23 Gearshift Mechanism Removal/Installation
1 ± SHIFTER ASSEMBLY
2 ± NUT (4)Fig. 24 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
PLTRANSAXLE 21 - 77
REMOVAL AND INSTALLATION (Continued)

(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. 27).
This allows cable to self adjust.
(4) Press locking clip to secure cable position (Fig.
28).
(5) Road test vehicle to verify proper transaxle
operation.BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Loosen set screw and remove knob from shifter
handle (Fig. 29).
(3) Remove the center console assembly as shown
in (Fig. 30).
Fig. 27 Throttle Valve Cable Adjustment
1 ± TAB UNLOCKED
Fig. 28 Cable Locking Clip
1 ± TAB LOCKED
2 ± THROTTLE VALVE CABLE
Fig. 29 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 30 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
PLTRANSAXLE 21 - 79
REMOVAL AND INSTALLATION (Continued)

(4) Remove shifter bezel (Fig. 31).
(5) Disconnect the shifter/ignition interlock cable
from the shifter lever and bracket as shown in (Fig.
32). Remove the cable core end from the plastic cam
of the shifter mechanism and release cable from
shifter bracket
(6) Remove the steering column lower cover (Fig.
33).
(7) Remove the steering column upper and lower
shrouds (Fig. 34).(8) Disconnect the Brake Transmission Shift Inter-
lock (BTSI) solenoid connector from the interlock
cable (Fig. 35).
(9) Rotate the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 36).
(10) Squeeze the interlock cable locking tab.
Remove the cable from the interlock housing (Fig.
37).
(11) Release cable from retaining clips and remove
through opening under steering column.
Fig. 31 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 32 Interlock Cable at Shifter Assembly
1 ± INTERLOCK CABLE
2 ± SHIFTER ASSEMBLY
Fig. 33 Steering Column Lower Cover
1 ± LOWER COVER
Fig. 34 Steering Column Shrouds
1 ± UPPER SHROUD
2 ± LOWER SHROUD
21 - 80 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
CAUTION: When installing interlock cable assem-
bly, care must be taken not to bend exposed cable
wire and slug at shifter end of cable.(1) Route interlock cable through hole in instru-
ment panel below steering column and around to
gear shifter assembly.
(2) Turn the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 36).
(3) Install the interlock cable into the interlock
housing at the steering column (Fig. 38). Verify the
cable snaps into the housing and is fully seated.
(4) Return the ignition key to the ªLOCKº position
(Fig. 36).
(5) Connect the BTSI solenoid connector (Fig. 35).
(6) Install cable into retaining clips as shown in
(Fig. 35).
(7) Install steering column upper and lower
shrouds (Fig. 34).
(8) Install steering column lower cover (Fig. 33).
Fig. 35 Interlock Cable at Steering Column
1 ± IGNITION SWITCH
2 ± CLIP
3 ± INTERLOCK CABLE
4 ± BTSI SOLENOID
Fig. 36 Ignition Key/Switch Positions
1 ± ACC
2 ± LOCK
3 ± OFF
4 ± ON/RUN
5±START
Fig. 37 Interlock Cable and Connector
1 ± IGNITION LOCK CYLINDER
2 ± INTERLOCK CABLE
Fig. 38 Interlock Cable at Interlock Housing
1 ± IGNITION SWITCH
2 ± INTERLOCK CABLE
PLTRANSAXLE 21 - 81
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)

(3) Install steering column upper and lower
shrouds (Fig. 40).
(4) Install steering column lower cover (Fig. 39).
VEHICLE SPEED SENSOR PINION GEAR
REMOVAL
(1) Remove harness connector from sensor (Fig.
44). Be sure weather seal stays on harness connector.
(2) Remove bolt securing the sensor in the exten-
sion housing (Fig. 44).
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor (Fig. 44).
(5) Inspect pinion gear for damage (missing teeth,
etc.) and replace as necessary.NOTE: When removing vehicle speed sensor for
any reason, a new o-ring MUST be used.
INSTALLATION
(1) Install pinion gear to vehicle speed sensor as
shown in (Fig. 44).
(2) Install sensor to extension housing using a
NEW o-ring.
(3) Tighten bolt to 7 N´m (60 in. lbs.).
(4) Connect harness connector.
Fig. 41 Ignition Key/Switch Positions
1 ± ACC
2 ± LOCK
3 ± OFF
4 ± ON/RUN
5±START
Fig. 42 Interlock Cable
1 ± IGNITION LOCK CYLINDER
2 ± INTERLOCK CABLE
Fig. 43 Interlock Mechanism
1 ± MOUNTING SCREW
2 ± INTERLOCK MECHANISM
Fig. 44 Vehicle Speed Sensor Removal/Installation
1 ± CONNECTOR
2 ± SPEEDO PINION
3 ± O-RING
4 ± SENSOR
PLTRANSAXLE 21 - 83
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)