tra DODGE NEON 2000 Service Repair Manual

(9) Install split thrust washer retaining ring (Fig.
111).
(10) Install 5th gear caged needle bearing (Fig.
112).
(11) Using special tool #C-3717, install 5th speed
gear and synchronizer (Fig. 113). The 5th gear syn-
chronizer hub has the letterSstamped on the top
face of the hub. This designates that the hub must be
installed with theSfacing upward.
(12) Install 5th gear synchronizer snap ring (Fig.
114).
Fig. 111 Retaining Ring Installation
1 ± SPLIT THRUST WASHER RING
2 ± INPUT SHAFT
Fig. 112 Caged Needle Bearing Installation
1 ± INPUT SHAFT
2 ± CAGED NEEDLE BEARING
Fig. 113 5th Speed Gear Installation
1 ± PRESS RAM
2 ± SPECIAL TOOL C-3717
3 ± SYNCHRONIZER ASSEMBLY
4 ± BEARING SPLITTER
5 ± 5TH SPEED GEAR
Fig. 114 5th Gear Synchronizer Snap Ring
Installation
1 ± SNAP RING PLIERS
2 ± INPUT SHAFT
3 ± BEARING SPLITTER
4 ± SNAP RING
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT
CAUTION: The output shaft 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 output shaft
assembly.
It is necessary to check the synchronizer stop ring
gap. Use a feeler gauge to measure the gaps between
the stop rings and the speed gears. The correct gaps
are listed below:
²1stÐ1.04-1.72 mm (0.041-0.069 in).
²2ndÐ0.94-1.72 mm (0.038-0.069 in).
²3rdÐ1.37-1.93 mm (0.054-0.076 in).
²4thÐ1.41-1.97 mm (0.056-0.078 in).
²5thÐ1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
cations it must be inspected for wear and replaced. If
the 1st or 2nd synchronizer stop ring is worn beyond
specifications, the complete output shaft assembly
must be replaced.
The output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 115).
DIFFERENTIAL
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle gear case
²Clutch bellhousing case
²Differential case
²Differential bearings
Refer toBearing Adjustment Procedurein the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
Fig. 115 Output Shaft
1 ± 1ST GEAR
2 ± SLEEVE
3 ± STOP RING
4 ± OUTPUT SHAFT
5 ± 2ND SPEED GEAR
6 ± REVERSE GEAR
7 ± STOP RING
Fig. 116 Remove Differential Bearing Cone
1 ± SPECIAL TOOL C-293-PA
2 ± SPECIAL TOOL C-4996
3 ± DIFFERENTIAL ASSEMBLY
4 ± SPECIAL TOOL C-293-45
21 - 36 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N´m (60 ft. lbs.) torque.
Fig. 117 Install Differential Bearing Cone
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL L-4410
3 ± BEARING CONE
4 ± SPEED SENSOR DRIVE GEAR
Fig. 118 Remove Differential Bearing Cone
1 ± SPECIAL TOOL C-293
2 ± SPECIAL TOOL ADAPTER C-293-45 (USE 4 PIECES)
3 ± DIFFERENTIAL ASSEMBLY
4 ± DIFFERENTIAL BEARING CONE
5 ± SPECIAL TOOL C-4996 (NOTE POSITION)
Fig. 119 Install Differential Bearing Cone
1 ± ARBOR PRESS RAM
2 ± BEARING CONE
3 ± SPECIAL TOOL HANDLE C-4171
4 ± SPECIAL TOOL L-4410
5 ± DIFFERENTIAL ASSEMBLY
Fig. 120 Remove or Install Ring Gear Bolts and
Ring Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± BEARING
3 ± RING GEAR
4 ± RING GEAR BOLTS
PLTRANSAXLE 21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)

SPEEDOMETER DRIVE GEAR
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
REMOVAL
(1) Pry the plastic speedometer drive gear off of
the differential case using a flat blade pry tool (Fig.
121) (Fig. 122).INSTALLATION
NOTE: A new speedometer drive gear must be
installed on differential assembly. The lip on the
speedometer drive gear must be positioned down-
ward when installing onto differential assembly.
(1) Position speedometer drive gear onto differen-
tial assembly (Fig. 123).
(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
124) (Fig. 125). Do not use a hammer.
Fig. 121 Pry Off Speedometer Drive Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 122 Speedometer Drive Gear Removed
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 123 Speedometer Drive Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 124 Press Gear onto Diferential
1 ± STEEL STOCK
2 ± PRESS RAM
3 ± SPECIAL TOOL L-4440
4 ± DIFFERENTIAL ASSEMBLY
5 ± SPEEDOMETER DRIVE GEAR
21 - 38 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL GEARS
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears. Refer to Speedometer
Drive Gear for service information.
REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 126)
(Fig. 127).(2) Remove pinion shaft (Fig. 128).
Fig. 125 Drive Gear Pressed onto Differential
1 ± PRESS RAM
2 ± SPEEDOMETER DRIVE GEAR
3 ± DIFFERENTIAL ASSEMBLY
Fig. 126 Remove Pinion Shaft Retaining Pin
1 ± RING GEAR
2 ± PINION SHAFT RETAINING PIN
3 ± SPEEDOMETER DRIVE GEAR
Fig. 127 Retaining Pin Removed
1 ± DIFFERENTIAL ASSEMBLY
2 ± SPEEDOMETER DRIVE GEAR
3 ± PINION SHAFT RETAINING PIN
Fig. 128 Pinion Shaft Removal
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± PINION SHAFT RETAINING PIN
PLTRANSAXLE 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Rotate side gears to opening in differential
(Fig. 129).
(4) Remove differential gears (Fig. 130).INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 131).
Fig. 129 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in Case
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± PINION SHAFT RETAINING PIN
5 ± PINION GEAR (2)
Fig. 130 Differential Gears
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± SIDE GEAR THRUST WASHERS (SELECT THICKNESS)5 ± PINION GEAR THRUST WASHERS
6 ± PINION GEARS
7 ± SIDE GEARS
8 ± PINION SHAFT RETAINING PIN
Fig. 131 Install Retaining Pin
1 ± PINION SHAFT RETAINING PIN
2 ± SPEEDOMETER DRIVE GEAR
21 - 40 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 132).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise.
(4) Set up dial indicator as shown and record end
play (Fig. 133) (Fig. 134). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear
90 degrees and record a final end play.
(5) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(6) After the end play is measured and adjusted,
replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
tion, refer to Speedometer Drive Gear service in this
section.
SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with theU
facing upward.
(2) Install springs into hub slot (Fig. 135).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 136).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 137).
(6) Line up stop ring tang over the keys in the hub
(Fig. 138). Install stop rings. Center the keys and
balls by pushing on both stop rings.
Fig. 132 Staking Retaining Pin
1 ± PINION SHAFT RETAINING PIN
2 ± SPEEDOMETER DRIVE GEAR
Fig. 133 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
4 ± SIDE GEAR
Fig. 134 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT RAILS OVERHAUL
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.
TRANSAXLE CASE OVERHAUL
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.
The components that are left in the gear cases
when the gear train is pulled out are the:
²Axle shaft seals
Fig. 135 Synchronizer Assembly
1 ± SLEEVE
2 ± BALL
3 ± KEY
4 ± SPRING
5 ± HUB
Fig. 136 Synchronizer Balls
1 ± INPUT SHAFT
2 ± HUB
3 ± KEY
4 ± BALL
Fig. 137 Synchronizer Sleeve
1 ± SLEEVE
2 ± INPUT SHAFT
3 ± KEY
Fig. 138 Keys in Hub
1 ± SNAP RING
2 ± CLUTCH
3 ± KEY
4 ± BALL
5 ± SPRING
21 - 42 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Output bearing race and retainer
²Input bearing and sleeve
²Differential bearing cones
²Shift rail bushings
²Shift shafts
²Shift shaft seals
²Shift shaft bushings
²Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
(1) Insert a flat±blade pry tool at outer edge of
axle shaft seal (Fig. 139).
(2) Tap on the pry tool with a small hammer and
remove axle shaft seal.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 with C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position (Fig. 140).
OUTPUT BEARING
REMOVAL
NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end±to±end.
Install bearing with larger diameter cage ring facing
out.(1) Remove caged roller bearing from output bear-
ing race (Fig. 141).
(2) Remove screws at output bearing retainer
strap (Fig. 142).
(3) Install tool #6787 and slide hammer (Fig. 143).
Tighten tool to output bearing race.
(4) Using slide hammer, remove output bearing
race.
Fig. 139 Axle Shaft Seal Removal
1 ± AXLE SEAL
2±PRYTOOL
Fig. 140 Axle Seal Installation
1 ± TOOL C-4171
2 ± TOOL 6709
3 ± AXLE SEAL
Fig. 141 Output Roller Bearing
1 ± INPUT BEARING
2 ± OUTPUT BEARING
3 ± LARGER DIAMETER CAGE RING
PLTRANSAXLE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-
ing race (Fig. 144). Tap race into bore. Install output
bearing into race. Verify that the larger diameter
cage is facing outward. Position bearing retaining
strap. Tighten bolts to 11 N´m (96 in. lbs.).
Fig. 142 Output Bearing Strap
1 ± BEARING RETAINER
2 ± OUTPUT BEARING RACE
Fig. 143 Output Bearing Race Removal
1 ± C-3752
2 ± SPECIAL TOOL 6787
3 ± OUTPUT SHAFT BEARING RACE
Fig. 144 Output Bearing Race Installation
1 ± TOOL C-4171
2 ± TOOL C-4628
3 ± OUTPUT BEARING RACE
21 - 44 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)