1999 DODGE NEON Service Repair Manual

STEERING GEAR TO STEERING COLUMN
COUPLING
This vehicle uses a corrugated design for the lower
coupling used to connect the steering column to the
steering gear (Fig. 2).
This coupling has a hollow corrugated tube (Fig. 2)
which allows the coupling to bend rather then
colapse when a vehicle is involved in a collision.
DIAGNOSIS AND TESTING
STEERING COLUMN
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning
of this group.
STEERING COLUMN TO STEERING GEAR
COUPLING
STEERING COLUMN COUPLING INSPECTION
The steering column couplingMUSTbe inspected
whenever a vehicle is involved in an impact or when-
ever any of the following conditions exist.
(1) The steering column coupling must be
inspected whenever a vehicle is involved in a colli-
sion which deploys the air bag, regardless of the
extent of damage done to the vehicle.
(2) If a vehicle is involved in an impact of the vehi-
cles front suspension or under carriage, which results
in any type of damage to the front suspension cross-
member.
(3) Under any conditions which result in the steer-
ing column assembly or steering column shaft receiv-
ing a force great enough to move the steering column
or shaft forward or rearward in a vehicle.
STEERING COUPLING INSPECTION
PROCEDURE
(1) Remove the pinch bolt safety pin from the
steering column shaft coupling pinch bolt (Fig. 3).
(2) Loosen the coupling pinch bolt retaining nut
and remove pinch bolt (Fig. 3) from steering coupler.
(Pinch bolt nut is caged to coupler and is not
removable.)Then separate the steering column
upper coupling from the lower coupling.
(3) Remove the silencer seal (Fig. 4) enclosing the
steering column coupling.
(4) Inspect steering column coupling in the follow-
ing areas for signs of damage:
²Inspect the sealing collar on the lower coupling
(Fig. 5) to ensure the it is not cracked, broken, or
otherwise damaged requiring coupling replacement.
²Inspect the corrugated section (Fig. 5) of the
lower coupling for the following conditions or any
other visible signs of damage.
²Uneven spacing between the corrugations on
the coupling.
Fig. 2 Steering Gear To Steering Column CouplingFig. 3 Steering Column To Coupling Attachment
Fig. 4 Steering Column Coupling Seal
19 - 36 STEERINGPL
DESCRIPTION AND OPERATION (Continued)

²Dings or dents in the corrugations of the cou-
pling or anywhere else on the coupling wall.
²A bend in the corrugated section of the cou-
pling.
If any of the preceding conditions exist the steering
couplingMUSTbe replaced.
The steering gear must be removed from the vehi-
cle to allow access for replacement of the lower cou-
pling. Refer to Steering Gear Service Procedures in
this group of the service manual for the required
steering gear removal procedure.
(5) If lower coupling does not require replacement,
install steering column upper coupling silencer seal
(Fig. 4) back on the vehicle.
(6) Ensure front wheels of vehicle are positioned
straight-ahead and then align and attach steering
column upper coupling to lower coupling (Fig. 3).
Install the coupling pinch bolt (Fig. 3). Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).Be
sure to install upper to lower steering coupling
pinch bolt safety pin (Fig. 3).REMOVAL AND INSTALLATION
STEERING COLUMN SERVICE PROCEDURE
WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times
when working on steering columns.
CAUTION: Disconnect negative (ground) cable
from the battery, before servicing any column com-
ponent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
Fig. 5 Steering Column Coupling Inspection
PLSTEERING 19 - 37
DIAGNOSIS AND TESTING (Continued)

STEERING COLUMN
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Before beginning removal of steering column
assembly from vehicle, be sure front wheels of vehicle
are in thestraight aheadposition.
(3) Remove the 4 screws attaching steering column
cover, to lower instrument panel. Then remove the
trim panel from the instrument panel (Fig. 6).
(4) Remove 3 screws (Fig. 7) attaching the steering
column cover liner to the instrument panel. Remove
the liner from the lower instrument panel.
(5) If vehicle is equipped with speed control,
remove the speed control switches from the steering
wheel (Fig. 8). If vehicle is not equipped with speed
control, remove the trim covers from the sides of the
steering wheel.WARNING: WHEN AN UNDEPLOYED AIR BAG
ASSEMBLY IS TO BE REMOVED FROM THE STEER-
ING WHEEL, DISCONNECT BATTERY GROUND
CABLE AND ISOLATE. ALLOW SYSTEM CAPACI-
TOR TO DISCHARGE FOR TWO MINUTES, THEN
BEGIN AIR BAG REMOVAL.
(6) Remove the 2 fasteners, 1 on each side of steer-
ing wheel, attaching the air bag module to the steer-
ing wheel (Fig. 9).
Fig. 6 Steering Column Cover
Fig. 7 Steering Column Cover Liner
Fig. 8 Speed Control Switches
Fig. 9 Air Bag Module Mounting Bolts
19 - 38 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

WARNING: WHEN HANDLING AN UNDEPLOYED
AIR BAG MODULE DURING SERVICING OF THE
STEERING COLUMN THE FOLLOWING PRECAU-
TIONS SHOULD BE OBSERVED. AT NO TIME
SHOULD ANY SOURCE OF ELECTRICITY BE PER-
MITTED NEAR THE INFLATOR ON THE BACK OF
THE AIR BAG MODULE. WHEN CARRYING A LIVE
MODULE, THE TRIM COVER SHOULD BE POINTED
AWAY FROM THE BODY TO MINIMIZE INJURY IF
MODULE ACCIDENTLY DEPLOYS. IF AIR BAG MOD-
ULE IS PLACED ON A BENCH OR OTHER SUR-
FACE, PLASTIC COVER SHOULD BE FACE UP TO
MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL
DEPLOYMENT.
(7) Remove air bag module from center of steering
wheel. Then disconnect the clock spring electrical
lead from the back of the air bag module (Fig. 10).
(8) Disconnect the wiring lead for the horn switch
in the airbag module from the wiring lead coming
from the clockspring (Fig. 11).
(9) Turn the lock cylinder to theoffposition and
remove the key from the lock cylinder
(10) Turn the steering wheel to the left 1/2 a turn
(180É) until the steering column lock is engaged (Fig.
12).
(11) Remove the steering wheel retaining nut,
from the steering column shaft (Fig. 12). If equipped,
remove the damper weight from the steering wheel.
CAUTION: When installing wheel puller on the
steering wheel be sure puller bolts are fully seated
in the threaded holes on the steering wheel. If bolts
are not fully seated in the threaded holes, the
threads may be stripped out of the steering wheel
when removing the steering wheel.
(12) Install Puller, Snap-On CJ2001P or an equiv-
alent on the steering wheel (Fig. 13).CAUTION: Do not bump or hammer on steering
wheel or steering column shaft when removing
steering wheel from steering column.
Fig. 11 Clock Spring To Horn Switch Wiring
Connection
Fig. 12 Steering Wheel Attaching Nut
Fig. 13 Steering Wheel Puller Installed
Fig. 10 Air Bag Module Electrical Connection
PLSTEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)

(13) Remove steering wheel assembly from steer-
ing column shaft using Puller, Special Tool C-3428-B
or equivalent.
(14) Remove key lock cylinder from steering col-
umn. Key lock cylinder is removed from steering col-
umn using the following procedure. Place the key
lock cylinder in the Run position. Then through the
hole in lower shroud, (Fig. 14) depress lock cylinder
retaining tab and remove key lock cylinder.
(15) Remove the 3 screws attaching the upper and
lower shroud to the steering column (Fig. 15). First
remove lower shroud from steering column, then
release tilt lever and tilt steering column to its low-
est point. Then remove upper shroud from steering
column.
(16) Remove retaining pin from pinch bolt in steer-
ing column upper coupling (Fig. 16).
(17) Loosen the steering column upper coupling
pinch bolt retaining nut and remove pinch bolt (Fig.
16) from steering coupling.(Pinch bolt nut iscaged to coupler and is not removable.)Then
separate steering column shaft coupling from lower
steering coupling.
(18) Remove the 2 nuts attaching the lower
mounting bracket of the steering column to the steer-
ing column mounting bracket.
(19) Remove the 2 nuts mounting the steering col-
umn upper bracket to the steering column support
bracket (Fig. 17).
(20) Lower steering column in the steering column
access opening of the lower instrument panel.
(21) Remove routing clip (Fig. 18) holding wiring
harness to jacket of steering column. Then remove
wiring harness connectors from the multi- function
switch and the windshield wiper switch (Fig. 18).
(22) Remove the vehicle wiring harness connec-
tors from the ignition switch and clock spring (Fig.
19).
Fig. 14 Key Lock Cylinder Access Hole In Steering
Column Shrouds
Fig. 15 Upper And Lower Steering Column Shrouds
Fig. 16 Upper To Lower Steering Column Coupler
Disassembly
Fig. 17 Steering Column Upper Support Bracket
Attaching Nuts
19 - 40 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(23) Remove steering column from vehicle through
the drivers door of the passenger compartment. Use
care to avoid damaging the paint or interior trim.
INSTALL
(1) Install steering column into steering column
access opening in lower instrument panel.
(2) Install the vehicle wiring harness connectors,
into the ignition switch and clock spring assembly
(Fig. 19).
(3) Install vehicle wiring harness connectors into
multi-function switch and turn signal switch (Fig. 18)
on steering column assembly. Install routing clip
(Fig. 18) holding wiring harness to jacket of steering
column.
(4) Install the studs in the steering column sup-
port bracket, into the slots in the aluminum capsules
in the upper mounting bracket of the steering column
(Fig. 17). Partially install the 2 upper steering col-
umn assembly mounting bracket to support bracketattaching nuts (Fig. 17).Do not tighten the 2
mounting nuts at this time.
(5) Install and securely tighten the 2 nuts mount-
ing the steering column lower mounting bracket to
the steering column support bracket.
(6) Install the upper and lower steering column
shrouds onto the lock housing of the steering column
assembly. Install and securely tighten the 3 upper to
lower steering column shroud to lock housing attach-
ing screws (Fig. 15).
(7) Be sure both breakaway capsules are still fully
seated in the slots of the upper steering column
mounting bracket. Equally tighten both steering col-
umn mounting nuts, until upper steering column
mounting bracket is seated against support bracket.
Then tighten the 2 steering column upper mounting
bracket nuts to a torque of 17 N´m (150 in. lbs.).
(8) Tighten the steering column lower mounting
bracket nuts (2) to a torque of 17 N´m (150 in. lbs.).
(9) Assemble the steering column flex coupler to
the intermediate steering coupler (Fig. 16). Install
the steering coupler pinch bolt. Torque the pinch bolt
nut to 28 N´m (250 in. lbs.).Be sure to install
upper to lower steering coupler pinch bolt
retaining pin (Fig. 16).
(10) Install the lower instrument panel steering
column cover liner onto lower instrument panel.
Install and securely tighten the 3 liner to instrument
panel attaching screws (Fig. 7).
(11) Install lower instrument panel steering col-
umn cover (Fig. 6) on lower instrument panel. Install
and securely tighten the 4 screws (Fig. 6) attaching
steering column cover, to lower instrument panel.
CAUTION: Clock spring centering procedure MUST
be performed prior to installing steering wheel
assembly. If clock spring is not centered it may be
overextended, causing clock spring assembly to
become inoperative.
(12) Center the clock spring using the following
procedure.
²Depress the 2 plastic locking pins to disengage
clockspring locking mechanism.
²Keeping locking mechanism disengaged, rotate
the clockspring rotor in the CLOCKWISE DIREC-
TION to the end of the travel. Do not apply excessive
torque.
²From the end of travel, rotate the rotor 2 full
turns and an additional half turn in the counter-
clockwise direction. (The horn wire should end up at
the top and the squib wire at the bottom.) Engage
the clockspring locking mechanism.
Fig. 18 Steering Column Wiring Connections
Fig. 19 Steering Column Wiring Connections
PLSTEERING 19 - 41
REMOVAL AND INSTALLATION (Continued)

CAUTION: Do not install steering wheel onto shaft
of steering column assembly by driving it onto the
shaft. Pull steering wheel down onto steering col-
umn shaft using ONLY the steering wheel retaining
nut.
(13) Feed clock spring wiring leads through hole in
steering wheel (Fig. 20). Position steering wheel on
shaft of steering column assembly, making sure to fit
flats on hub of steering wheel with formations on
inside of clockspring.
(14) Install steering wheel to steering column
shaft retaining nut and tighten until steering wheel
is fully installed on shaft. The tighten steering wheel
retaining nut to a torque of 61 N´m (45 ft. lbs.).
(15) Connect the clockspring electrical leads to
components such as horn switches and speed control
switches located in the steering wheel (Fig. 11).
(16) Install air bag electrical lead from clock
spring, into connector on back of air bag module (Fig.
10).Be sure electrical connector from clock-
spring is securely latched into air bag module
connector.
CAUTION: The fasteners, screws, and bolts, origi-
nally used for the air bag components are specifi-
cally designed for the air bag system. They must
never be replaced with any substitutes. Anytime a
new fastener is needed, replace only with correct
fasteners provided in service packages or fasteners
listed in the parts book.
(17) Install air bag module into center of steering
wheel. Align air bag module mounting holes with bolt
holes in steering wheel. Installonly the 2 original
or correct replacementair bag module attachingbolts (Fig. 9). Torque the 2 air bag module attaching
bolts to 10 N´m (90 in. lbs.).
(18) Install key lock cylinder into lock housing.
Key lock cylinder is installed by positioning key cyl-
inder in the run position so retaining tab can be
depressed and the pushing key cylinder into lock hos-
ing until retaining tab locks into key lock cylinder.
(19) Reconnect ground cable to Negative post of
the battery.When reconnecting battery on a
vehicle that has had the air bag module
removed, the following procedure should be
used.
²Remove forward console or cover as necessary.
²Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
²Turn ignition key to ON position. Exit vehicle
with the DRB II. Install the latest version of the
proper diagnostic cartridge into the DRB II.
²Ensuring that their are no occupants in the
vehicle, connect negative cable to negative post of the
battery.
²Using the DRB II read and record active fault
codes. Also read and record any stored fault codes.
Refer to the Passive Restraint Diagnostic Test Man-
ual if any faults are found.
²Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
²From the passenger side of the vehicle, turn
ignition key to OFF and then ON observing instru-
ment cluster air bag lamp. It should go on for six to
eight seconds, then go out. This will indicate that the
air bag system is functioning normally.
(20)If air bag warning lamp fails to light,
blinks on and off or goes on and stays on, there
is an air bag system malfunction.Refer to the
Passive Restraint Diagnostic Test Manual to diag-
nose the system malfunction.
(21) Test the operation of the horn, lights and any
other functions that are steering column operated. If
applicable reset the radio and the clock.
(22) Road test vehicle to ensure proper operation
of the steering system and the speed control system.
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
Steering Wheel
Retaining Nut...............61N´m(45ft.lbs.)
Steering Column Assembly
Upper And Lower Mounting Bracket
Attaching Nuts...........17N´m(150 in. lbs.)
Fig. 20 Steering Wheel Installation
19 - 42 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

TRANSAXLE
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE............. 40 NVT350 (A-578) MANUAL TRANSAXLE....... 1
NV T350 (A-578) MANUAL TRANSAXLE
INDEX
page page
GENERAL INFORMATION
GEAR RATIOS........................... 2
GEARSHIFT PATTERN..................... 2
NV T350 MANUAL TRANSAXLE.............. 1
SEALANTS.............................. 2
SELECTION OF LUBRICANT................ 2
SPECIAL ADDITIVES...................... 2
TRANSAXLE IDENTIFICATION INFORMATION . . . 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
SHIFT LEVERS.......................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS...................... 3
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 3
LOW LUBRICANT LEVEL................... 3
NOISY OPERATION....................... 3
SLIPS OUT OF GEAR..................... 3
SERVICE PROCEDURES
FLUID DRAIN AND FILL.................... 3
REMOVAL AND INSTALLATION
AXLE SEALS............................ 8
BACK-UP LAMP SWITCH................... 7
CROSSOVER LEVER...................... 7
GEARSHIFT BOOT....................... 4
GEARSHIFT CABLES...................... 4GEARSHIFT KNOB....................... 4
GEARSHIFT MECHANISM REPLACEMENT..... 6
SELECTOR LEVER....................... 8
SHIFT SHAFT SEALS...................... 8
TRANSAXLE............................ 8
VEHICLE SPEED SENSOR DRIVE GEAR...... 7
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 24
INPUT SHAFT.......................... 20
OUTPUT SHAFT........................ 24
SHIFT RAILS OVERHAUL................. 29
SYNCHRONIZER........................ 29
TRANSAXLE CASE OVERHAUL............. 30
TRANSAXLE........................... 10
CLEANING AND INSPECTION
SYNCHRONIZER........................ 35
TRANSAXLE........................... 35
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 35
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT......................... 36
GEARSHIFT CROSSOVER CABLE........... 35
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS.......... 37
SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE....... 37
GENERAL INFORMATION
NV T350 MANUAL TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This five speed is a constant-mesh manual tran-
saxle. All gear ranges, except reverse, are synchro-
nized. The reverse gear utilizes a brake and blockingring for shifting ease. The reverse idler gear is sup-
ported on a sliding spindle idler shaft. The transaxle
case is aluminum with a steel end±plate bearing
cover. It is housed in a die-cast aluminum case fea-
turing a two±piece, middle split design.
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
PLTRANSAXLE 21 - 1