tra DODGE NEON 2000 Service Repair Manual

INPUT BEARING AND SLEEVE
The input bearing is a one±piece bearing and
sleeve unit (Fig. 145). The sleeve is the slide point for
the clutch±release bearing and lever.
REMOVAL
(1) Install tool #6342 over input bearing on the
gear case side of the transaxle clutch housing.
(2) Press the input bearing out of the housing (Fig.
146).INSTALLATION
(1) Apply coating of Loctitetsealant on bearing
outer diameter. Position sleeve and bearing assembly
at input bearing bore.
(2) Install tool #C-4680-1 over input bearing (Fig.
147).
(3) Using the spacer tool #4894 and shop press,
install input bearing into bore until it is fully seated
(Fig. 148).
Fig. 145 Input Bearing And Sleeve
1 ± DIFFERENTIAL BEARING
2 ± OUTPUT BEARING
3 ± INPUT BEARING
4 ± BEARING RETAINER
Fig. 146 Input Bearing Removal
1 ± SPECIAL TOOL 6342
2 ± BELLHOUSING HALF
3 ± INPUT BEARING AND SLEEVE
Fig. 147 Input Bearing Tool
1 ± SPECIAL TOOL C-4680-1
2 ± SPECIAL TOOL 4894
3 ± BELLHOUSING HALF
Fig. 148 Input Bearing Installed
1 ± SLEEVE AND BEARING ASSEMBLY
PLTRANSAXLE 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL BEARING CUPS
REMOVAL
(1) Remove differential assembly from gear case
using the procedure outlined in this group.
(2) Install Miller tool #L-4518 into the differential
bearing cup (Fig. 149).
(3) Install the tool cup over the tool (Fig. 150).
(4) Tighten the tool until the race is removed from
the case.INSTALLATION
(1) Position the bearing cup into the case.
(2) Install the bearing cup onto Miller tool
#L-4520.
(3) Using Miller tool #L-4520 and C-4171 driver,
install differential bearing cup into the transaxle
case.
SHIFT RAIL BUSHINGS
REMOVAL
(1) Thread tool #6786 into shift rail bushing.
(2) Install slide hammer #3752 onto tool.
(3) Remove bushing using slide hammer and tool
assembly (Fig. 151).
INSTALLATION
(1) Line up replacement bushing in bore.
(2) Using tool #MD998343, tap bushing into bore
until flush with the chamfer in the case.
SHIFT SHAFT SEALS
It is not necessary to remove the shift shafts from
the transaxle to service the shift shaft seals.
REMOVAL
(1) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep-well socket.
Fig. 149 Tool Installed in Bearing
1 ± SPECIAL TOOL L-4518
2 ± GEAR CASE
Fig. 150 Tool Cup Installed
1 ± GEAR CASE
2 ± SPECIAL TOOL L-4518
3 ± WRENCH
Fig. 151 Shift Rail Bushing Removal
1 ± SPECIAL TOOL 6786
2 ± SLIDE HAMMER C-3752
3 ± SHIFTER RAIL BUSHING
4 ± INPUT BEARING
21 - 46 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT SELECTOR SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
selector shaft by pushing on the shaft from the out-
side. Pull shaft out from the inside.
INSTALLATION
(1) Reverse removal procedure to install selector
shaft.
SHIFT CROSSOVER SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
crossover shaft seal.
(3) Using snap±ring pliers, remove the snap ring
at the crossover shaft bore (Fig. 152).
(4) Push the crossover shaft in the case and
remove the crossover assembly.
INSTALLATION
(1) Reverse removal procedure to install crossover
shaft.
SHIFT SELECTOR SHAFT BUSHING
REMOVAL
(1) Remove selector shaft using procedure in this
group.
(2) Thread tool #6786 into bushing.
(3) Install slide hammer #3752 onto tool and
remove bushing using slide hammer (Fig. 153).
INSTALLATION
(1) Position replacement bushing over selector
shaft bore.
(2) Using an appropriate size deep±well socket,
install bushing in selector shaft bore (Fig. 154).
Fig. 152 Crossover Shaft Snap Ring
1 ± SELECTOR SHAFT
2 ± CROSSOVER SHAFT
3 ± SNAP RING
Fig. 153 Selector Shaft Bushing Removal
1 ± SPECIAL TOOL 6786
2 ± SHIFT SHAFT BUSHING
3 ± SLIDE HAMMER C-3752
Fig. 154 Selector Shaft Bushing Installation
1 ± DEEP WELL SOCKET
2 ± SHIFTER SHAFT BUSHING
PLTRANSAXLE 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT CROSSOVER SHAFT BUSHING
REMOVAL
(1) Install slide hammer #3752 through the cross-
over bushing.
(2) Thread nut and washer onto slide hammer.
(3) Using the slide hammer, remove the crossover
shaft bushing (Fig. 155).
INSTALLATION
(1) Position the replacement crossover shaft bush-
ing over the crossover shaft bushing bore.
(2) Using an appropriate size deep±well socket,
install the crossover shaft bushing into the bushing
bore.
REAR BEARING OIL FEED TROUGH
The bearing oil feed trough is retained in the case
by a pin that is molded into the case and clips that
are part of the trough (Fig. 156).
REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust wash-
ers. Replace the bearings and cups if the rollers are
worn, chipped, cracked, flat spotted, or brinnelled, or if
the bearing cage is damaged or distorted. Replace the
thrust washers if cracked, chipped, or worn. Replace
the gears if the teeth are chipped, cracked, or worn
thin. Inspect the synchronizers. Replace the sleeve if
worn or damaged in any way. Replace the stop rings if
the friction material is burned, flaking off, or worn.
Check the condition of the synchro keys and springs.
Replace these parts if worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
Fig. 155 Crossover Shaft Bushing Removal
1 ± SLIDE HAMMER
2 ± SHIFTER SHAFT BUSHING
Fig. 156 Oil Feed Trough
1 ± OIL FEED TROUGH
21 - 48 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (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)

(8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
Step 7. Then press the bearing cup into clutch bell-
housing.
(9) Install clutch bellhousing. Install and torque
case bolts to 26 N´m (19 ft. lbs.).
(10) Using Special Tool C-4995 and an inch-pound
torque wrench, check turning torque of the differen-
tial assembly (Fig. 164).The turning torque
should be 6 to 12 in. lbs. If the turning torque is
too high, install a 0.05mm (0.002 inch) thinner
shim. If the turning torque is too low, install a
0.05mm (0.002 inch) thicker shim.(11) Recheck turning torque. Repeat Step 10until
the proper turning torque is obtained.
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS
DESCRIPTION TORQUE
Back-up Lamp Switch........ 24N´m(18ft.lbs.)
Crossover Cable Adj. Screw.... 8N´m(70in.lbs.)
Drain Plug............... 28N´m(250 in. lbs.)
Differential Ring Gear Bolts . . . 81 N´m (60 ft. lbs.)
Dust Shield to Transaxle.... 12N´m(105 in. lbs.)
End Plate Cover Bolts........ 29N´m(21ft.lbs.)
Lateral Bending Strut to Engine......... 81N´m
(60 ft. lbs.)
Lateral Bending Strut to Trans.......... 81N´m
(60 ft. lbs.)
Left Mount Through Bolt.... 108N´m(80ft.lbs.)
Left Mount to Transaxle...... 68N´m(50ft.lbs.)
Output Bearing Race Ret. Strap......... 11N´m
(96 in. lbs.)
Reverse Fork Bracket........ 11N´m(96in.lbs.)
Reverse Idler Shaft Bolt...... 26N´m(19ft.lbs.)
Shift Cable Bracket to Transaxle........ 28N´m
(250 in. lbs.)
Transaxle Case Bolts......... 29N´m(21ft.lbs.)
Transaxle to Engine Bolt...... 95N´m(70ft.lbs.)
Trans. to Eng. Intake Bkt. Bolts......... 95N´m
(70 ft. lbs.)
Vehicle Speed Sensor......... 7N´m(60in.lbs.)
Vertical Bending Strut to Engine........ 81N´m
(60 ft. lbs.)
Vertical Bending Strut to Trans.......... 81N´m
(60 ft. lbs.)
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
Fig. 163 Checking Differential Bearing End Play to
Determine Shim Thickness
1 ± T-HANDLE
2 ± DIAL INDICATOR SET
3 ± SPECIAL TOOL C-4995
Fig. 164 Checking Differential Bearing Turning
Torque
1 ± INCH-POUND TORQUE WRENCH
2 ± SPECIAL TOOL C-4995
NV T350 (A-578) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLE METRIC
MEASUREU. S.
MEASURE
NV T350 1.9-2.2 Liters 2.0-2.3 Quarts
PLTRANSAXLE 21 - 51
ADJUSTMENTS (Continued)

SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE
Adapter Blocks C-293±45
Puller Press C-293±PA
Dial Indicator C-3339
Sleeve C-3717
Slide Hammer C-3752
Universal Handle C-4171
Bearing Installer C-4628
Seal Remover C-4680
Seal Installer C-4992
Torque Tool C-4995
21 - 52 TRANSAXLEPL

Adapter C-4996
Installer L-4410
Special Jaw Set L-4518
Bearing Splitter 1130
Driver 6342
Seal Installer 6709
Bearing Remover 6768
Bench Fixture 6785
Remover 6786
Remover 6787
PLTRANSAXLE 21 - 53
SPECIAL TOOLS (Continued)

31TH AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
GENERAL INFORMATION
IN VEHICLE SERVICE.....................55
FLUID REQUIREMENTS...................55
DESCRIPTION AND OPERATION
31TH GENERAL INFORMATION..............55
FLUID LEVEL AND CONDITION..............56
TORQUE CONVERTER CLUTCH.............56
HYDRAULIC CONTROL SYSTEM.............56
PRESSURE SUPPLY SYSTEM...............56
PRESSURE REGULATING VALVES...........56
FLOW CONTROL VALVES..................56
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR........................57
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM..............................57
GEARSHIFT AND PARKING LOCK CONTROLS . . 57
COOLER BYPASS VALVE..................57
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR...................58
GOVERNOR.............................58
DIAGNOSIS AND TESTING
TRANSAXLE PRELIMINARY DIAGNOSIS.......58
ROAD TEST.............................65
HYDRAULIC PRESSURE TESTS.............66
CLUTCH AND SERVO AIR PRESSURE TESTS . . 68
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA.............70
BRAKE TRANSMISSION SHIFT INTERLOCK....70
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE.....70
ALUMINUM THREAD REPAIR...............71
FLUSHING COOLERS AND TUBES...........72
OIL PUMP VOLUME CHECK................72
REMOVAL AND INSTALLATION
GEARSHIFT CABLE.......................73
GEARSHIFT MECHANISM..................76
THROTTLE VALVE (KICKDOWN) CABLE.......77
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE...............................79
INTERLOCK MECHANISM..................82
VEHICLE SPEED SENSOR PINION GEAR......83
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH.........................84TRANSAXLE AND TORQUE CONVERTER......84
PUMP OIL SEAL.........................88
DISASSEMBLY AND ASSEMBLY
TRANSAXLE............................89
VALVE BODY............................91
OIL PUMP.............................104
FRONT CLUTCH........................105
REAR CLUTCH ASSEMBLY................108
FRONT PLANETARY AND ANNULUS
GEAR-RECONDITION...................110
LOW/REVERSE (REAR) SERVO-
RECONDITION........................112
ACCUMULATOR-RECONDITION............113
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................113
TRANSFER SHAFT REPAIR................114
PARKING PAWL.........................121
OUTPUT SHAFT REPAIR..................121
DIFFERENTIAL REPAIR...................129
CLEANING AND INSPECTION
VALVE BODY...........................135
ADJUSTMENTS
GEARSHIFT CABLE......................135
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE.........................136
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM.............................137
BAND ADJUSTMENT.....................138
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS.......................138
BEARING ADJUSTMENT PROCEDURES......138
OUTPUT SHAFT BEARING................139
DIFFERENTIAL BEARING.................139
TRANSFER SHAFT BEARING..............140
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 142
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE.............150
31TH TRANSAXLE TORQUE SPECIFICATIONS . 150
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE.............151
21 - 54 TRANSAXLEPL