differential DODGE NEON 2000 Service Workshop Manual

Fig. 73 Kickdown Band and Strut
1 ± FRONT CLUTCH
2 ± KICKDOWN BAND
3 ± OIL RETURN AND FEED HOLE TO DIFFERENTIAL
4 ± STRUT
Fig. 74 Front Clutch Assembly
1 ± REAR CLUTCH ASSEMBLY
2 ± FRONT CLUTCH ASSEMBLY
Fig. 75 No. 2 Thrust Washer and Rear Clutch
1 ± REAR CLUTCH ASSEMBLY
2 ± #2 THRUST WASHER
Fig. 76 No. 3 Thrust Washer
1 ± OUTPUT SHAFT
2 ± SUN GEAR DRIVING SHELL
3 ± #3 THRUST WASHER (SELECT FIT)
PLTRANSAXLE 21 - 93
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)

OUTPUT SHAFT BEARING
With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shim on the planetary rear annulus gear hub using
grease to hold the shim in place. The 13.65 mm shim
has a larger inside diameter and must be installed
over the output shaft first. The 1.34 mm shim pilots
on the output shaft.
Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
To measure bearing end play:
(1) Attach Tool L-4432 to the output shaft gear.
(2) Mount a steel ball with grease into the end of
the output shaft.
(3) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(4) Using a dial indicator mounted to the transaxle
case, measure output shaft end play.
(5) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(6) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
that are necessary for proper bearing lubrica-
tion.
(7) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(8) Use tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use tool
L-4407.
(9) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.
(10) Install the retaining nut and washer, and
torque to 271 N´m (200 ft. lbs.).
(11) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(12) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
DIFFERENTIAL BEARING
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft.
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential.
OUTPUT SHAFT BEARING SHIM CHART
Fig. 222 Tool L-4436 and Torque Wrench
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
3 ± DIFFERENTIAL BEARING RETAINER
PLTRANSAXLE 21 - 139
ADJUSTMENTS (Continued)

The turning torque should be between 5 and 18
inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e)
NOTE: If the turning torque was too high when
measured, install a.05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a.05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differen-
tial.The turning torque should be between 5
and 18 inch-pounds.
TRANSFER SHAFT BEARING
(1) Use tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
a. Attach tool L-4432 to the transfer gear.
b. Mount a steel ball with grease into the end of
the transfer shaft.
c. Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
d. Using a dial indicator, measure transfer shaft
end play.
e. Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
f. Use tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using tool
L-4407.
Fig. 223 Checking Differential Bearings Turning
Torque
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
21 - 140 TRANSAXLEPL
ADJUSTMENTS (Continued)

SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
Type .........Automatic three speed with torque
converter and integral differential
Torque Converter Diameter...... 241millimeters
(9.48 in.)
OilType .....................MopartATF+4
(Automatic Transmission Fluid) Type 9602
Cooling Method.... Water Heat Exchanger and/or
air to oil heat exchanger
Lubrication . . . Pump (internal-external gear-type)
Transmission Gear Ratios
First Gear............................2.69
Second Gear...........................1.55
Third Gear............................1.00
Reverse Gear..........................2.10
Band Adjustment
KickdownÐBacked Off From 8 N²m
(72 in. lbs.).................... 21/4Turns
Low-ReverseÐBacked Off From 5 N²m
(41 in. lbs.).................... 31/2Turns
Clutch Pack Clearances
Front Clutch (Not Adjustable)......1.27-2.79mm
(0.050-0.110 in.)
Rear Clutch.......0.71-1.10mm (0.028-0.043 in.)
End Play
Input Shaft........0.19±1.50 mm (.008±.060 in.)
Front Clutch Retainer...........0.76±2.69 mm
(.030±.106 in.)
Front Carrier.......0.89±1.45 mm (.007±.057 in.)
Front Annulus Gear . . 0.09±0.50 mm (.0035±.020 in.)
Planet Pinion.......0.15±0.59 mm (.006±.023 in.)
Reverse Drum......0.76±3.36 mm (.030±.132 in.)
Oil Pump Clearances
Outer Gear To Pocket...........0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . 6 to 12 in. lbs. Drag Torque
Output Hub.......... 0to3in.lbs. Drag Torque
Transfer Shaft.......0.002 to 0.010 in. End Play
Overall Drag At Output
Hub ............. 3to16in.lbs. Drag TorqueThrust Washers
Reaction Shaft Support (No. 1).....1.55±1.60 mm
(.061±.063 in.)
Rear Clutch Retainer (No. 2)......1.55±1.60 mm
(.061±.063 in.)
Output Shaft (No. 3) (Select)......1.98±2.03 mm
(.077±.080 in.)
Output Shaft (No. 3) (Select)......2.15±2.22 mm
(.085±.087 in.)
Output Shaft (No. 3) (Select)......2.34±2.41 mm
(.092±.095 in.)
Front Annulus (No. 4)............2.95±3.05 mm
(.116±.120 in.)
Front Carrier (Nos. 5&6).........1.22±1.28 mm
(.0948±.050 in.)
Sun Gear-Front (No. 7)...........0.85±0.91 mm
(.033±.036 in.)
Sun Gear-Rear (No. 8)...........0.85±0.91 mm
(.033±.036 in.)
Rear Carrier (Nos. 9&10).........1.22±1.28 mm
(.0948±.050 in.)
Rev. Drum (No. 11) . . 1.55±1.60 mm (.061±.063 in.)
31TH TRANSAXLE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Bell Housing Cover Bolts.... 12N´m(105 in. lbs.)
Cooler Line Clamps.......... 2N´m(18in.lbs.)
Diff. Bear. Ret. To Case Bolt . . 34 N´m (300 in. lbs.)
Diff. Cover To Case Bolt..... 19N´m(165 in. lbs.)
Exten. Hous. To Case Bolt . . . 28 N´m (250 in. lbs.)
Drive Plate To Crankshaft
Bolts................... 95N´m(70ft.lbs.)
Drive Plate To Torque Conv.
Bolts................... 88N´m(65ft.lbs.)
Fluid Filter Screw........... 5N´m(45in.lbs.)
Governor Counterweight
Screw................. 28N´m(250 in. lbs.)
Governor To Support Bolt...... 7N´m(60in.lbs.)
Kickdown Band Adj. Lock Nut . . 47 N´m (35 ft. lbs.)
Left Motor Mount Bolts....... 54N´m(40ft.lbs.)
Manual Cable To Trans.
Case Bolt.............. 28N´m(250 in. lbs.)
Manual Control Lever Screw . . 12 N´m (105 in. lbs.)
Oil Pan To Trans. Case
Screw................. 19N´m(165 in. lbs.)
Output Gear Strap Bolts...... 23N´m(17ft.lbs.)
Output Shaft Nut......... 271N´m(200 ft. lbs.)
Park/Neutral Switch......... 34N´m(25ft.lbs.)
Pressure Check Plug......... 5N´m(45in.lbs.)
Pump To Case Bolts........ 31N´m(275 in. lbs.)
Reaction Shaft Assembly
Bolt................... 28N´m(250 in. lbs.)
Rear Cover To Case Screw . . . 19 N´m (165 in. lbs.)
Reverse Band Adj. Lock Nut . . 14 N´m (125 in. lbs.)
21 - 150 TRANSAXLEPL