tra DODGE NEON 2000 Service Repair Manual

INSTALLATION
(1) Install cable assembly through floor pan open-
ing and secure to floor pan with grommet plate and
one screw (Fig. 16). Make sure the three grommet
plate studs protrude through cable assembly and
floor pan and tighten screw to 7 N´m (60 in. lbs.).
(2) Route transaxle end of cable assembly into
engine compartment and over transaxle assembly.
(3) Install and tighten intermediate pipe heat
shield front screws.
(4) Install catalytic converter heat shield (Fig. 15).
(5) Install gear shift cable to bracket and connect
to shift lever (Fig. 14).
(6) Install and tighten the three grommet plate-to-
floor pan nuts. Tighten to 6 N´m (50 in. lbs.) torque.
(7) Connect gearshift cable to shifter assembly as
shown in (Fig. 12).
(8) Install shifter bezel (Fig. 11).
(9)Adjust gearshift cable as follows:
(a) Place gearshift lever in the PARK (P) posi-
tion.
(b) Loosen shift cable adjustment screw (Fig.
17).
(c) Verify transaxle is in the PARK (P) position
and the shifter lever is in gated PARK..
(d) Tighten shift cable adjustment screw to 8
N´m (70 in. lbs.) torque.
(10) Install battery tray.
(11) Install battery and hold down clamp.
(12) Install the air cleaner/throttle body assy. (Fig.
13) as follows:(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(13) Install center console assembly (Fig. 10).
(14) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 9).
(15) Connect battery cables.
(16) Verify that engine starter operates in both
PARK (P) and NEUTRAL (N). Starter should not
operate in any other gear position.
Fig. 16 Grommet Plate/Shift Cable at Floor Pan
1 ± GROMMET PLATE
2 ± SHIFT CABLE
Fig. 17 Gearshift Cable Adjustment Screw
1 ± GEARSHIFT CABLE ADJUSTMENT SCREW
PLTRANSAXLE 21 - 75
REMOVAL AND INSTALLATION (Continued)

GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable and isolate.
(2) Loosen set screw and remove knob from shifter
handle (Fig. 18).
(3) Remove the center console assembly as shown
in (Fig. 19).(4) Remove shifter bezel (Fig. 20).
(5) Disconnect shift cable from shifter assembly as
shown in (Fig. 21).
Fig. 18 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 19 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 20 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 21 Gearshift Cable at Shifter Assembly
1 ± SHIFTER ASSEMBLY
2 ± GROMMET PLATE NUT
3 ± SHIFT CABLE
21 - 76 TRANSAXLEPL
REMOVAL AND INSTALLATION (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)

(2) Disconnect throttle valve cable from air clean-
er/throttle body assembly as shown in (Fig. 25).
(3) Disconnect throttle valve cable from lever on
transaxle and remove from bracket (Fig. 26).INSTALLATION
NOTE: Route throttle valve cable in a manner that
allows free, unobstructed travel. For proper tran-
saxle operation, the cable must not bind.
(1) Install transaxle throttle valve cable to bracket
and lever as shown in (Fig. 26). Make sure the cable
snapsonto the lever.
(2) Install the throttle valve cable to the air clean-
er/throttle body as shown in (Fig. 25).
(3) Install the air cleaner/throttle body assy. as fol-
lows:
(a) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(b) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(c) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(d) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(4) Connect the battery negative cable.
(5) Perform the Throttle Valve Cable Adjustment
Procedure found in this group.
(6) Road test vehicle and verify proper transaxle
operation.
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE
The transmission throttle valve is operated by a
cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine
throttle body lever.
The throttle valve is located within the transaxle
valve body and is responsible for transaxle shift
speed, shift quality, and part-throttle downshift sen-
sitivity. Proper cable adjustment is essential for
proper transaxle operation.
NOTE: The air cleaner/throttle body assembly must
be installed into position before making this adjust-
ment.
Fig. 25 Throttle Valve Cable at Air Cleaner/Throttle
Body
1 ± KICKDOWN CABLE
2 ± AIR CLEANER/THROTTLE BODY ASSY.
Fig. 26 Throttle Valve Cable at Transaxle
1 ± LEVER
2 ± BRACKET
3 ± KICKDOWN CABLE
21 - 78 TRANSAXLEPL
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)

PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH
TEST
The park/neutral starting switch is the center ter-
minal of the three terminal switch. It provides
ground for the starter solenoid circuit through the
selector lever in PARK and NEUTRAL positions only.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in PARK or NEUTRAL.
(2) Check gearshift cable adjustment before replac-
ing a switch that tests bad.
REMOVAL
(1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
PARK, then to NEUTRAL position, and inspect to see
the switch operating lever fingers are centered in
switch opening.
INSTALLATION
(1) Screw the switch with a new seal into tran-
saxle case and tighten to 33 N´m (24 ft. lbs.). Retest
switch with the test lamp.
(2) Add fluid to transaxle to bring up to proper
level.
(3) The back-up lamp switch circuit is through the
two outside terminals of the three terminal switch.
(4) To test switch, remove wiring connector from
switch and test for continuity between the two out-
side pins.
(5) Continuity should exist only with transaxle in
REVERSE position.
(6) No continuity should exist from either pin to
the case.
TRANSAXLE AND TORQUE CONVERTER
REMOVAL
(1) Raise hood.
(2) Disconnect both battery cables, remove battery
hold down clamp and bolt, and remove battery.
(3) Remove air cleaner/throttle body assy. (Fig. 45)
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) Remove mounting bolt and nut (Fig. 45) and
partially remove air cleaner assembly.
(d) Disconnect accelerator, transaxle kickdown,
and speed control (if equipped) cables after the
assy. is removed from position. Remove air cleaner
assembly from vehicle.(4) Remove battery tray from bracket.
(5) Disconnect torque converter clutch solenoid and
neutral safety/back-up lamp switch connectors.
(6) Disconnect and plug transaxle oil cooler lines
(Fig. 46).
(7) Disconnect shifter cable from shift lever and
remove from bracket (Fig. 47). Secure cable out of the
way.
Fig. 45 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
Fig. 46 Transaxle Oil Cooler Lines
1 ± RETURN
2 ± CLAMPS
3 ± PRESSURE
21 - 84 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)