tra DODGE NEON 2000 Service Repair Manual

ASSEMBLY
Fig. 174 Remove Output Shaft Gear Bearing Cup
1 ± OUTPUT SHAFT GEAR BEARING CUP
2 ± SPECIAL TOOL L-4518
Fig. 175 Remove Rear Planetary Annulus Gear
Bearing Cup
1 ± REAR PLANETARY ANNULUS GEAR BEARING CUP
2 ± SPECIAL TOOL L-4518
Fig. 176 Install Output Shaft Gear Bearing Cone
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4408
4 ± OUTPUT SHAFT GEAR
5 ± BEARING CONE
Fig. 177 Install Rear Planetary Annulus Gear
Bearing Cone
1 ± ARBOR PRESS RAM
2 ± SPECIAL TOOL C-4637
3 ± REAR PLANETARY ANNULUS GEAR
4 ± CUP FROM TOOL L-4518
5 ± BEARING CONE
PLTRANSAXLE 21 - 125
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearing turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 178 Install Output Shaft into Rear Planetary
Annulus Gear
1 ± PRESS
2 ± 1/2 INCH SOCKET
3 ± OUTPUT SHAFT
4 ± REAR ANNULUS GEAR
5 ± SPACER
Fig. 179 Install Output Shaft Gear Bearing Cup
1 ± OUTPUT SHAFT GEAR BEARING CUP
2 ± SPECIAL TOOL L-4429-3
Fig. 180 Install Rear Planetary Annulus Gear
Bearing Cup
1 ± SPECIAL TOOL L-4429-3
Fig. 181 Install Output Shaft Assembly
1 ± OUTPUT SHAFT ASSEMBLY
2 ± USE GREASE TO HOLD SHIMS IN POSITION
3 ± BEARING CONE
4 ± LUBRICATION HOLE
5 ± SELECT SHIMS
21 - 126 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 182 Output Shaft and (Select) Shims in Position
1 ± BEARING CUP
2 ± (SELECT) SHIM
3 ± OUTPUT SHAFT ASSEMBLY
Fig. 183 Start Output Shaft Gear onto Output Shaft
1 ± OUTPUT SHAFT GEAR
2 ± OUTPUT SHAFT
3 ± SPECIAL TOOL L-4439
Fig. 184 Holding Output Shaft Gear
1 ± OUTPUT SHAFT
2 ± SCREW (2)
3 ± SPECIAL TOOL L-4434 AND C-4658
4 ± WASHER
5 ± NUT
Fig. 185 Tighten Output Shaft Retaining Nut to 271
N´m (200 ft. lbs.)
1 ± OUTPUT SHAFT GEAR
2 ± SPECIAL TOOL L-4434 AND C-4658
3 ± SCREW (2)
Fig. 186 Checking Output Shaft End Play
1 ± SPECIAL TOOL L-4432 AND C-4658
2 ± SCREW (2)
3 ± OUTPUT SHAFT GEAR
4 ± STEEL BALL (GREASE IN PLACE)
5 ± SPECIAL TOOL L-4438
6 ± DIAL INDICATOR
PLTRANSAXLE 21 - 127
DISASSEMBLY AND ASSEMBLY (Continued)

STIRRUP AND RETAINING STRAP
INSTALLATION
Once bearing turning torque and shim selection
has been adjusted, install stirrup and strap assembly
onto output gear.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.
(1) Position the stirrup on the output gear.
(2) Position strap.
(3) Install retaining bolts into output gear. Finger±
tighten bolts.
(4) Turn stirrup clockwise against the flats of the
output gear retaining nut (Fig. 188).
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.)
(Fig. 189).
(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
Fig. 187 Checking Bearing Turning Torque
1 ± OUTPUT SHAFT GEAR
2 ± TORQUE WRENCHFig. 188 Turn Stirrup Clockwise Against Flats Of
Retaining Nut
1 ± TURN STIRRUP CLOCKWISE
2 ± STRAP
Fig. 189 Tighten Strap Retaining Nuts
1 ± STRAP
2 ± OUTPUT GEAR
3 ± STIRRUP
21 - 128 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for
differential repair and bearing turning torque check-
ing.
Fig. 190 Remove Extension Seal
1 ± EXTENSION HOUSING
2 ± SMALL CHISEL
3 ± HAMMER
4 ± OIL SEAL
Fig. 191 Install New Seal into Extension
1 ± SPECIAL TOOL L-4520 (INVERTED)
2 ± HANDLE C-4171
3 ± HAMMER
4 ± EXTENSION HOUSING
Fig. 192 Differential Cover Bolts
1 ± DIFFERENTIAL COVER
2 ± DIFFERENTIAL COVER BOLT
Fig. 193 Remove or Install Differential Cover
1 ± GOVERNOR PRESSURE PLUG
2 ± DIFFERENTIAL COVER
3 ± 1/8 INCH BEAD OF R T V SEALANT
4 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 129
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential cover.
Fig. 194 Remove Bearing Retainer Axle Seal
1 ± SPECIAL TOOL 7794A
2 ± SPECIAL TOOL C-637
3 ± DIFFERENTIAL BEARING RETAINER
Fig. 195 Install Bearing Retainer Axle Seal
1 ± SPECIAL TOOL L-4520
2 ± SPECIAL TOOL C-4171
Fig. 196 Differential Bearing Retainer Bolts
1 ± DIFFERENTIAL BEARING RETAINER
2 ± DIFFERENTIAL BEARING RETAINER BOLTS (6)
Fig. 197 Remove or Install Bearing Retainer
1 ± GOVERNOR PRESSURE PLUG
2 ± DIFFERENTIAL BEARING RETAINER
3 ± SPECIAL TOOL L-4435
21 - 130 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential bearing retainer.
Fig. 198 Differential Bearing Retainer (Typical)
1 ± DIFFERENTIAL BEARING CUP
2 ± DIFFERENTIAL
3 ± DIFFERENTIAL BEARING RETAINER
Fig. 199 Extension Bolts
1 ± EXTENSION HOUSING BOLTS (4)
2 ± EXTENSION HOUSING
3 ± OIL SEAL
Fig. 200 Remove or Install Extension Housing
1 ± EXTENSION HOUSING
2 ± DIFFERENTIAL ASSEMBLY
3 ± SPECIAL TOOL L-4435
Fig. 201 Differential and Extension
1 ± EXTENSION HOUSING
2 ± ªOº RING
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 131
DISASSEMBLY AND ASSEMBLY (Continued)

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use MopartSilicone Rubber Adhesive Sealant, or
equivalent, when installing extension housing.
Fig. 202 Remove Differential Bearing Cone
(Extension Housing Side)
1 ± SPECIAL TOOL C-293
2 ± SPECIAL TOOL C-293-36
3 ± SPECIAL TOOL C-293-3
Fig. 203 Position Bearing Cone Onto Differential
1 ± DIFFERENTIAL ASSEMBLY
2 ± DIFFERENTIAL BEARING
Fig. 204 Install Differential Bearing Cone
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL 6536
3 ± DIFFERENTIAL ASSEMBLY
Fig. 205 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
1 ± SPECIAL TOOL L-4539-2
2 ± SPECIAL TOOL 5048
3 ± SPECIAL TOOL 5048-4
21 - 132 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

To install the differential bearing cup and cone on
the ring gear side, use Special Tool 5052, and Special
Tool C-4171.NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
CAUTION: Side gear end play must be BETWEEN
0.001 to 0.013 inch.
Fig. 206 Position Tool 5048 Over Button and Collets
at Differential Bearing
1 ± SPECIAL TO0L 5048
2 ± DIFFERENTIAL
3 ± SPECIAL TOOL 5048-4
Fig. 207 Remove Differential Bearing Cone
1 ± SPECIAL TOOL 5048
2 ± RING GEAR
Fig. 208 Checking Side Gear End Play
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
4 ± SIDE GEAR
Fig. 209 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 133
DISASSEMBLY AND ASSEMBLY (Continued)

To remove the differential bearing cup from the
extension housing/adapter side, use Special Tool
6062A, Remover. To install the differential bearing
cup on the extension housing/adapter side, use Spe-
cial Tool 6536, Driver and Special Tool C-4171, Han-
dle.
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
Fig. 210 Differential Bearing Retainer
1 ± DIFFERENTIAL BEARING CUP
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 211 Position Bearing Cup Remover Tool in
Retainer
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 212 Remove Bearing Cup
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 213 Install Bearing Cup
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL 5052
3 ± DIFFERENTIAL BEARING RETAINER
21 - 134 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)