tra DODGE NEON 2000 Service Repair Manual

NOTE: Remove old sealant before applying new
sealant. Use MoparTRTV sealant, or equivalent,
when installing cover.
STIRRUP AND STRAP REMOVAL
NOTE: A stirrup and retaining strap is attached to
the transfer gear. The stirrup prevents the transfer
gear retaining nut from turning and backing off the
transfer shaft. The strap is used to hold the stirrup
to the transfer gear and prevent the stirrup retain-
ing bolts from backing out.
(1) Using a punch, bend tabs on strap flat against
transfer gear.
(2) Remove bolts holding retaining strap to stir-
rup.
(3) Remove strap from transfer gear and stirrup.
(4) Remove stirrup from transfer gear.
Fig. 136 Remove or Install Rear Cover
1 ± OUTPUT SHAFT GEAR
2 ± USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 ± REAR COVER
4 ± TRANSFER SHAFT GEAR
Fig. 137 Remove Transfer Shaft Gear Retaining Nut
1 ± TRANSFER SHAFT GEAR
2 ± SCREW (2)
3 ± OUTPUT SHAFT GEAR
4 ± SPECIAL TOOL L-4434
Fig. 138 Transfer Shaft Gear Nut and Washer
1 ± OUTPUT SHAFT GEAR
2 ± TRANSFER SHAFT GEAR
3 ± WASHER
4 ± NUT
PLTRANSAXLE 21 - 115
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 139 Remove Transfer Shaft Gear using L-4407A
1 ± TRANSFER GEAR
2 ± TOOL L-4407A
Fig. 140 Transfer Shaft Gear and (Select) Shim
1 ± TRANSFER SHAFT GEAR
2 ± OUTPUT SHAFT GEAR
3 ± SHIM (SELECT)
4 ± BEARING CONE
Fig. 141 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
1 ± SPECIAL TOOL L-4406-1
2 ± TRANSFER SHAFT GEAR
Fig. 142 Install Transfer Shaft Gear Bearing Cone
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4410
4 ± TRANSFER SHAFT GEAR
5 ± BEARING CONE
21 - 116 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 143 Governor Support Retainer
1 ± TRANSFER SHAFT
2 ± OUTPUT SHAFT GEAR
3 ± BEARING CUP
4 ± GOVERNOR SUPPORT RETAINER
Fig. 144 Remove Governor Support Retainer
Bearing Cup
1 ± PRESS
2 ± HANDLE C-4171 (WITH SPECIAL TOOL L-4517)
3 ± GOVERNOR SUPPORT RETAINER
Fig. 145 Install Governor Support Retainer Bearing
Cup
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4520
4 ± GOVERNOR SUPPORT RETAINER
5 ± BEARING CUP
Fig. 146 Low/Reverse Band Anchor Pin
1 ± LOW-REVERSE BAND ANCHOR PIN
2 ± OUTPUT SHAFT GEAR
PLTRANSAXLE 21 - 117
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Remove or install both governor valves and
governor body.
Fig. 147 Governor Assembly
1 ± TRANSFER SHAFT
2 ± OUTPUT SHAFT GEAR
3 ± GOVERNOR ASSEMBLY
Fig. 148 Transfer Shaft Bearing Snap Ring
1 ± SNAP RING PLIERS
2 ± SNAP RING
3 ± OUTPUT SHAFT GEAR
4 ± TRANSFER SHAFT
Fig. 149 Remove Transfer Shaft and Bearing
Retainer Assembly
1 ± SPECIAL TOOL L-4512
2 ± SPECIAL TOOL L-4437
3 ± SPECIAL TOOL C-3752
Fig. 150 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
1 ± OUTPUT SHAFT GEAR
2 ± O-RING
3 ± SPECIAL TOOL L-4512
4 ± BEARING RETAINER ASSEMBLY
5 ± TRANSFER SHAFT
21 - 118 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 151 Transfer Shaft and Bearing Retainer
1 ± O-RING
2 ± TRANSFER SHAFT
3 ± BEARING CONE
4 ± TRANSFER SHAFT BEARING RETAINER
Fig. 152 Remove Transfer Shaft Bearing Cone
1 ± TOOL C-293-52
2 ± TRANSFER SHAFT
3 ± TOOL C-293-PA
4 ± VISE
Fig. 153 Install Transfer Shaft Bearing Cone
1 ± PRESS
2 ± SPECIAL TOOL L-4411
3 ± BEARING CONE
4 ± TRANSFER SHAFT
Fig. 154 Remove Transfer Shaft Bearing Cup
1 ± SPECIAL TOOL L-4518
2 ± TRANSFER SHAFT BEARING RETAINER
3 ± ªOº RING
4 ± BEARING CUP
PLTRANSAXLE 21 - 119
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Transfer shaft
²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
STIRRUP AND STRAP INSTALLATION
Once bearing shim selection has been adjusted,
install stirrup and strap assembly onto transfer gear.
NOTE: Once the stirrup assembly is positioned
onto the transfer gear, it is necessary to ªclockº the
stirrup against the flats of the transfer gear retain-
ing nut.
(1) Position the stirrup on the transfer gear.
(2) Position strap.
(3) Install retaining bolts into transfer gear. Fin-
ger±tighten bolts.
(4) Turn stirrup clockwise against the flats of the
transfer gear retaining nut.
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.).(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
Fig. 155 Install Transfer Shaft Bearing Cup
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4520
4 ± TRANSFER SHAFT BEARING RETAINER
5 ± ªOº RING
Fig. 156 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 ± TRANSFER SHAFT GEAR
2 ± TORQUE WRENCH
3 ± SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 157 Checking Transfer Shaft End Play
1 ± SPECIAL TOOL L-4432 AND C-4658
2 ± TRANSFER SHAFT GEAR
3 ± STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 ± DIAL INDICATOR
5 ± SCREW (2)
21 - 120 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

PARKING PAWL
DISASSEMBLY
ASSEMBLY
To install, reverse the above procedure.
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
STIRRUP AND RETAINING STRAP
NOTE: A stirrup and retaining strap (Fig. 161) is
attached to the output gear. The stirrup prevents
the output gear retaining nut from turning and
backing off the output shaft. The strap is used to
hold the stirrup to the output gear and prevent the
stirrup retaining bolts from backing out.
REMOVAL
Fig. 158 Parking Sprag Rod Support
1 ± PARKING SPRAG ROD SUPPORT
2 ± BOLT (2)
3 ± OUTPUT SHAFT GEAR
Fig. 159 Support and Bolts
1 ± BOLT (2)
2 ± PARKING SPRAG ROD SUPPORT
Fig. 160 Parking Pawl, Return Spring, and Pivot
Shaft
1 ± PARKING PAWL
2 ± RETURN SPRING
3 ± NOTE: SMALL DIAMETER TO REAR
4 ± PIVOT SHAFT
Fig. 161 Stirrup and Retaining Strap Assembly
1 ± STRAP
2 ± RETAINING BOLTS (2)
3 ± OUTPUT GEAR
4 ± STIRRUP
PLTRANSAXLE 21 - 121
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Using a punch, bend tabs on strap flat against
output gear (Fig. 162).
(2) Remove bolts holding retaining strap to stirrup
(Fig. 163).(3) Remove strap from output gear and stirrup
(Fig. 164).
(4) Remove stirrup from output gear (Fig. 165)
(Fig. 166).
Fig. 162 Bend Strap Tabs Flat
1 ± RETAINING TABS
2 ± STRAP
Fig. 163 Remove Strap Bolts
1 ± RETAINING BOLTS
2 ± STIRRUP
3 ± STRAP
Fig. 164 Remove Strap From Stirrup and Gear
1 ± OUTPUT GEAR
2 ± STRAP
Fig. 165 Remove Stirrup From Gear
1 ± OUTPUT GEAR
2 ± STIRRUP
21 - 122 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT GEAR AND SHAFT
DISASSEMBLY
Fig. 166 Stirrup and Strap Removed From Output
Gear
1 ± OUTPUT GEAR RETAINING NUT
2 ± OUTPUT GEAR
Fig. 167 Remove Output Shaft Retaining Nut and
Washer
1 ± SPECIAL TOOL L-4434
2 ± OUTPUT SHAFT GEAR
Fig. 168 Remove Output Shaft Gear using L-4407A
1 ± OUTPUT GEAR
2 ± TOOL L-4407A
Fig. 169 Output Shaft Gear and (Select) Shim
1 ± BEARING CUP
2 ± SHIM (SELECT)
3 ± BEARING CONE
4 ± OUTPUT SHAFT GEAR
5 ± OUTPUT SHAFT
PLTRANSAXLE 21 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 170 Remove Output Shaft Gear Bearing Cone
1 ± SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 ± OUTPUT SHAFT GEAR
Fig. 171 Remove Output Shaft and Rear Annulus
Gear Assembly
1 ± BEARING CUP
2 ± REAR ANNULUS GEAR
3 ± OUTPUT SHAFT
Fig. 172 Remove Output Shaft
1 ± ARBOR PRESS RAM
2 ± CAUTION: SUPPORT ANNULUS GEAR UNDERNEATH,
NEAR GEAR CENTER.
3 ± BEARING CONE
4 ± REAR ANNULUS GEAR
5 ± OUTPUT SHAFT
Fig. 173 Remove Rear Planetary Annulus Gear
Bearing Cone
1 ± SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 ± REAR PLANETARY ANNULUS GEAR
21 - 124 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)