clutch DODGE NEON 2000 Service Manual Online

INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 30).
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 30).
(3) Install the bolt and torque to 7 N´m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 30).
(5) Lower vehicle and road test to verify proper
speedometer operation.
BACK-UP LAMP SWITCH
The back-up lamp switch is located on the top left
front side of the transaxle case (Fig. 31).
REMOVAL
(1) Lift vehicle on hoist.
(2) From bottom side of vehicle, disconnect back-up
lamp switch connector.
(3) Unscrew switch from transaxle.
INSTALLATION
(1) Install back-up lamp switch. Teflon tape or
equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Connect back-up lamp switch connector.
(3) Lower vehicle.
(4) Verify back-up lamp operation.
CROSSOVER LEVER
REMOVAL
(1) Disconnect crossover cable from crossover lever
and cable bracket. Refer to Gearshift Cable Removal
and Installation in this Group.
(2) Using a pin punch, remove the crossover roll
pin from lever.
(3) Pull up and remove the crossover lever from
the transaxle crossover shaft (Fig. 32).
INSTALLATION
(1) Install crossover lever to shaft and fasten with
NEW roll pin.
(2) Install crossover cable to bracket. Fasten with
clip.
(3) Install crossover cable to crossover lever.
SELECTOR LEVER
The selector lever is retained to the shaft by two
roll pins (one inside the other).
REMOVAL
(1) Disconnect the selector cable from the selector
lever (Fig. 33) and remove from cable bracket. Refer
to Gearshift Cable Removal and Installation in this
Group.
(2) Using a pin punch, remove both roll pins from
the lever.
(3) Pull up and remove the selector lever from the
transaxle selector shaft.
Fig. 31 Back-up Lamp Switch
1 ± CLUTCH CABLE
2 ± BACK-UP LAMP SWITCH
3 ± LEFT FRAME RAIL
Fig. 32 Crossover Lever
1 ± CROSSOVER LEVER
2 ± CROSSOVER CABLE
3 ± SELECTOR CABLE
4 ± SELECTOR LEVER
21 - 12 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

TRANSAXLE
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. 36)
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. 36) and
partially remove air cleaner assembly.
(e)
Disconnect accelerator 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 ground cable at battery tray
bracket.
(6) Disconnect back-up lamp switch connector.
(7) Remove bellhousing cap (Fig. 37).
(8) Disconnect clutch cable from fork and remove
from transaxle (Fig. 37).(9) Remove shift cable-to-bracket clips (Fig. 38).
(10) Disconnect shift selector and crossover cable
from levers (Fig. 38). Remove cables and secure out
of the way.
Fig. 36 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
Fig. 37 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
Fig. 38 Shift Cables at Transaxle
1 ± SHIFT CABLES
2 ± CLIPS
3 ± BRACKET
21 - 14 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(11) Disconnect the vehicle speed sensor connector
(Fig. 39).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 40).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 40).
(17) Remove bellhousing dust cover (Fig. 40).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 41).
(19) Remove starter motor (Fig. 42).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 43).
Fig. 39 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINION
Fig. 40 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 41 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
PLTRANSAXLE 21 - 15
REMOVAL AND INSTALLATION (Continued)

(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 44).(25) Remove transaxle from vehicle (Fig. 44).
(26) If installing a new or replacement transaxle,
remove the upper mount as shown in (Fig. 45), trans-
fer to the replacement unit and torque all bolts to 68
N´m (50 ft. lbs.) torque.
INSTALLATION
(1) Install clutch module onto input shaft. Install
transaxle into position.
(2) Install transaxle-to-engine mounting bolts (Fig.
44) and tighten to 95 N´m (70 ft. lbs.) torque.
(3) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (80 ft. lbs.) torque (Fig. 43).
(4) Remove screwjack.
(5) Install drive plate-to-clutch module bolts and
torque to 88 N´m (65 ft. lbs.) torque.
(6) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 42).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 40).
(9) Install left engine-to-transaxle bending brace
(Fig. 40).
(10) Install structural collar (Fig. 40) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(11) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 41).
(12) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(13) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(14) Lower vehicle.
(15) Connect vehicle speed sensor connector (Fig.
39).
(16) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 38).
(17) Connect clutch cable to fork and secure to
transaxle (Fig. 37).
(18) Install bellhousing cap (Fig. 37).
(19) Connect back-up lamp switch connector.
(20) Connect ground strap to transaxle upper
mount bracket.
(21) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
Fig. 42 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 43 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 16 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(22) Install the air cleaner/throttle body assy. 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.
(23) Connect the battery cables.
(24) Road test vehicle and inspect for leaks.
Fig. 44 Transaxle Removal/Installation
1 ± MODULAR CLUTCH ASSEMBLY
2 ± CLIP3 ± TRANSAXLE
4 ± CLUTCH MODULE BOLT (4)
Fig. 45 Transaxle Upper Mount and Bracket
1 ± MOUNT
2 ± TRANSAXLE
PLTRANSAXLE 21 - 17
REMOVAL AND INSTALLATION (Continued)

DISASSEMBLY AND ASSEMBLY
TRANSAXLE
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
CAUTION: The transaxle output shaft is serviced as
a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench.
(2) Remove the clutch release bearing and fork.
Move the release fork and bearing to an in-line posi-
tion. Grasp the release lever with two hands in the
pivot stud socket area. Pull with even pressure to
release the fork from the pivot stud.
CAUTION: Do not use a screwdriver or pry bar to
release the fork as this may cause damage to the
fork and/or clip.
(3) Remove shift levers by driving out the roll pins.
(4) Remove transaxle case half bolts (Fig. 46).
(5) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 47). Separate
the case halves (Fig. 48).
Fig. 46 Case Bolts
1 ± CASE BOLTS
Fig. 47 Transaxle Case Halves
1 ± BELLHOUSING HALF
2 ± GEAR CASE HALF
Fig. 48 Separate Case Halves
1±PRYTOOL
2 ± CASE HALVES
3 ± PRY SLOT
21 - 18 TRANSAXLEPL

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. 94). 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.
(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. 95).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 10 until
the proper turning torque is obtained.
Once proper turning torque has been established,
place gear case on the end plate. Draw a bead of
MopartGasket Maker, Loctitet518, or equivalent,
on the flat surface of the case mating flange. Install
clutch bellhousing onto gear case. Install and tighten
case bolts to 29 N´m (21 ft. lbs.).
Fig. 94 Checking Differential Bearing End Play To
Determine Shim Thickness
1 ± T-HANDLE
2 ± DIAL INDICATOR SET
3 ± SPECIAL TOOL C-4995
Fig. 95 Checking Differential Bearing Turning
Torque
1 ± INCH-POUND TORQUE WRENCH
2 ± SPECIAL TOOL C-4995
21 - 30 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT
CAUTION: The output shaft is serviced as an
assembly. Do not try to repair any component on
the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the output shaft
assembly.
It is necessary to check the synchronizer stop ring
gap. Use a feeler gauge to measure the gaps between
the stop rings and the speed gears. The correct gaps
are listed below:
²1stÐ1.04-1.72 mm (0.041-0.069 in).
²2ndÐ0.94-1.72 mm (0.038-0.069 in).
²3rdÐ1.37-1.93 mm (0.054-0.076 in).
²4thÐ1.41-1.97 mm (0.056-0.078 in).
²5thÐ1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
cations it must be inspected for wear and replaced. If
the 1st or 2nd synchronizer stop ring is worn beyond
specifications, the complete output shaft assembly
must be replaced.
The output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 115).
DIFFERENTIAL
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle gear case
²Clutch bellhousing case
²Differential case
²Differential bearings
Refer toBearing Adjustment Procedurein the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
Fig. 115 Output Shaft
1 ± 1ST GEAR
2 ± SLEEVE
3 ± STOP RING
4 ± OUTPUT SHAFT
5 ± 2ND SPEED GEAR
6 ± REVERSE GEAR
7 ± STOP RING
Fig. 116 Remove Differential Bearing Cone
1 ± SPECIAL TOOL C-293-PA
2 ± SPECIAL TOOL C-4996
3 ± DIFFERENTIAL ASSEMBLY
4 ± SPECIAL TOOL C-293-45
21 - 36 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT RAILS OVERHAUL
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.
TRANSAXLE CASE OVERHAUL
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end±plate cover is
MopartRTV.
The components that are left in the gear cases
when the gear train is pulled out are the:
²Axle shaft seals
Fig. 135 Synchronizer Assembly
1 ± SLEEVE
2 ± BALL
3 ± KEY
4 ± SPRING
5 ± HUB
Fig. 136 Synchronizer Balls
1 ± INPUT SHAFT
2 ± HUB
3 ± KEY
4 ± BALL
Fig. 137 Synchronizer Sleeve
1 ± SLEEVE
2 ± INPUT SHAFT
3 ± KEY
Fig. 138 Keys in Hub
1 ± SNAP RING
2 ± CLUTCH
3 ± KEY
4 ± BALL
5 ± SPRING
21 - 42 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

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)