1999 DODGE NEON Service Repair Manual

CAUTION: The transaxle output shaft is serviced as
a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
TRANSAXLE IDENTIFICATION INFORMATION
The transaxle model, assembly number, and build
date are on a metal I.D. tag that is attached to the
end cover of the transaxle (Fig. 1). This information
is also shown on a bar code label that is attached to
the front of the transaxle.
NOTE: Transaxles use various final drive gear
ratios in different vehicle applications. Therefore, it
is necessary that the correct transaxle assembly
number is used when ordering service parts.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on the case, below the
back±up lamp switch.
NOTE: There are four different versions of this
transaxle. There are no external differences
between the models. Refer to the identification tag
on the transaxle to determine which transaxle the
vehicle is equipped with.
SELECTION OF LUBRICANT
NV T350 (A-578) transaxles use MopartType M.S.
9417 Manual Transaxle Fluid.Hypoid gear lube,
engine oil, and/or automatic transmission fluid
should not be used in this transaxle.Hard shift-
ing effort, bearing, gear, and/or synchronizer failure
may occur if incorrect fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes toaid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
SEALANTS
The sealant used to seal the transaxle case halves
and input bearing is MopartGasket Maker, Loctitet
518, or equivalent. The sealant used for the bearing
end plate cover is MopartRTV.
GEAR RATIOS
CAUTION: All gears and shafts must not be inter-
changed with other transaxles; they will not func-
tion correctly.
The differential is a conventional arrangement of
gears that is supported by tapered roller bearings.
The final output gear turns the ring gear and differ-
ential assembly, thereby turning the drive axle
shafts.
All transaxles have a torque capacity of 136 lb. ft.
The gear ratios of each transaxle are shown in the
following chart. The chart also shows which transax-
les are available with the reverse±input shaft brake.
This brake allows easier shifting into reverse and
helps eliminate reverse gear clash.
ENGINE 2.0 SOHC
EUROPE
AND U.S.1.8 BUX or
2.0L
SALES
CODE
ACR1.8 RIGHT
HAND
DRIVE
ONLY
GEAR
1st 3.54 3.54 3.54
2nd 2.13 2.13 2.13
3rd 1.36 1.36 1.36
4th 1.03 1.03 1.03
5th 0.72 0.81 0.81
FINAL
DRIVE3.55 3.94 3.94
REVERSE
BRAKENO YES YES
CLUTCH
RELEASE
SYSTEMCABLE CABLE HYDRAULIC
GEARSHIFT PATTERN
The NV T350 (A-578) transaxle shift pattern is a
modified H±pattern (Fig. 2). Overdrive fifth and
reverse gears are in±line and outboard of the first
through fourth gear positions.
Fig. 1 Metal I.D. Tag
21 - 2 TRANSAXLEPL
GENERAL INFORMATION (Continued)

DESCRIPTION AND OPERATION
SHIFT LEVERS
The shift levers are serviceable in the vehicle. The
shift levers are different from each other and do not
interchange.
SELECTOR LEVER
The selector shaft uses a lever with a weight on
the end. The weight is used to improve shift feel and
reduce noise.
The selector lever is retained by two roll pins (one
inside the other).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings, or
gear teeth may be worn or damaged.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
All NV T350 (A-578) transaxles are equipped with
a fill plug. The fill plug is located on the left side of
the transaxle differential area (Fig. 3). The fluid level
should be within 3/16 inch from the bottom of the
transaxle fill hole (vehicle must be level when check-
ing).
All NV T350 (A-578) transaxles are equipped with
a drain plug. The drain plug is located on the lower
right side of the transaxle differential housing (Fig.
4). Tighten drain plug to 28 N´m (250 in. lbs.)
Dry fill lubricant capacity is approximately 1.9-2.2
liters (4.0-4.6 pints). Wipe the outside of the tran-
saxle if any lubricant spills.
Fig. 2 NV T350 (A-578) Shift Pattern
PLTRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)

REMOVAL AND INSTALLATION
GEARSHIFT KNOB
REMOVAL
(1) Pull shifter boot down and away from shifter
roll pin.
(2) Pry legs of shift knob away from shift lever roll
pin using a flat blade pry tool.
(3) Remove knob from shifter handle (Fig. 5).
INSTALLATION
(1) For installation, reverse removal procedure.
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Remove the console assembly. Refer to Group
23, Body.(3) Snip the plastic retaining clips at the base of
the boot (Fig. 6). Remove the boot from the gearshift
mechanism.
INSTALLATION
(1) For installation, reverse removal procedure.
Install new plastic retaining clips.
GEARSHIFT CABLES
Use this procedure if either of the shift cables
require replacement.
REMOVAL
(1) Disconnect Power Distribution Center from
battery tray and set aside.
(2) Remove air cleaner inlet horn.
(3) Remove battery and battery tray.
(4) Disconnect gear shift cable ends from transaxle
shift levers (Fig. 7) (Fig. 8).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 5 Gearshift Knob
Fig. 6 Gearshift Boot
Fig. 3 Fill Plug Location
Fig. 4 Drain Plug Location
21 - 4 TRANSAXLEPL
SERVICE PROCEDURES (Continued)

(5) Remove cable to bracket retaining clips at tran-
saxle.
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(6) Pull cables up out of transaxle bracket.
(7) Remove console from vehicle. Refer to Group
23, Body.
(8) Remove floor pan grommet retaining nuts (Fig.
9).
(9) Remove cable retaining clips at shifter (Fig.
10).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(10) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.(11) Lift vehicle on hoist. Remove self-tapping
screw securing grommet plate to underbody heat
shield and floor pan (Fig. 11).
Fig. 7 Selector Cable Removal
Fig. 8 Crossover Cable Removal
Fig. 9 Grommet Retaining Nuts (Interior)
Fig. 10 Cable Retaining Clips
Fig. 11 Grommet Retaining Screw (Underbody)
PLTRANSAXLE 21 - 5
REMOVAL AND INSTALLATION (Continued)

(12) Detach cables from cable support clip in tun-
nel above exhaust catalyst.
(13) Remove shift cable assembly from vehicle.
INSTALLATION
CAUTION: Gearshift cable bushings must not be
lubricated or the bushings will swell and split.
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CROSSOVER CABLE
ADJUSTMENT
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 12).
(3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 13). Be sure drill bit goes into transaxle
case at least one half inch.
(4) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shifter knob.
(2) Remove console assembly. Refer to Group 23,
Body for procedure.
(3) Remove shifter boot.
(4) Disconnect gearshift cables at shifter end.
(5) Remove the parking brake mechanism. Refer to
Group 5, Brakes for procedure.
(6) Remove the airbag control module. Refer to
Group 8M, Passive Restraint System for procedure.
(7) Remove the two remaining nuts at the base of
the gearshift mechanism (Fig. 14). Remove shifter.
INSTALLATION
(1) For installation, reverse removal procedure.
Fig. 12 Crossover Cable Adjustment Screw
Fig. 13 Crossover Lever Pin Procedure
Fig. 14 Gearshift Mechanism
21 - 6 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

VEHICLE SPEED SENSOR DRIVE GEAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove wiring connector from speed sensor.
CAUTION: Clean area around speed sensor before
removing. This prevents the possibility of dirt from
entering the transaxle during speed sensor
removal.
(3) Remove speed sensor retaining bolt (Fig. 15).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into tran-
saxle. Should sensor drive gear fall into the tran-
saxle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) To install, reverse removal procedure.
(2) Confirm vehicle speedometer is functioning
properly following installation.
BACK-UP LAMP SWITCH
The back-up lamp switch is located on the top left
front side of the transaxle case (Fig. 16).
REMOVAL
(1) Lift vehicle on hoist.
(2) From bottom side of vehicle, remove wiring
connector from switch.
(3) Unscrew switch from transaxle.
INSTALLATION
(1) To install, reverse removal procedure. Teflon
tape or equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Confirm back-up lamps are functioning prop-
erly following installation.
CROSSOVER LEVER
REMOVAL
(1) Remove crossover cable. Refer to Gearshift
Cable removal.
(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. 17).
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pin that was removed with a new
one.
Fig. 15 Speed Sensor Retaining Bolt
Fig. 16 Back-up Lamp Switch
Fig. 17 Crossover Lever
PLTRANSAXLE 21 - 7
REMOVAL AND INSTALLATION (Continued)

SELECTOR LEVER
The selector shaft uses a lever with a weight on
the end. The weight is used to improve shift±feel and
reduce noise.
The selector lever is retained by two roll pins (one
inside the other).
REMOVAL
(1) Remove the selector cable. Refer to Gearshift
Cable removal.
(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
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pins that were removed with new
ones. The correct orientation for the roll pins is
shown in (Fig. 18).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool at outer edge of
axle shaft seal (Fig. 19).
(3) Tap on the pry tool with a small hammer and
remove axle shaft seal.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 and C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position.
SHIFT SHAFT SEALS
It isnotnecessary to remove the shift shafts from
the transaxle to service the shift shaft seals.
REMOVAL
(1) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep±well socket.
TRANSAXLE
NOTE: The transaxle can be removed from the
vehicle without having to remove the engine.
All transaxle components are serviced with the
transaxle out of the vehicle with the exception of:
²Selector shaft seal
²Crossover shaft seal
²End plate
²Axle shaft seals
²Shift levers
²Back up lamp switch
²Vehicle speed sensor
REMOVAL
(1) Disconnect the battery.
(2) Pull Power Distribution Center up and out of
its holding bracket. Set Power Distribution Center
aside to gain clearance.
(3) Remove battery heat shield and remove battery
from engine compartment. Remove battery tray from
engine compartment. Disconnect cruise control (if
equipped).
(4) Remove vehicle speed sensor wire.
(5) Disconnect back-up lamp switch wiring at tran-
saxle.
Fig. 18 Correct Orientation of Roll Pins
Fig. 19 Axle Shaft Seal Removal
21 - 8 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushing to avoid damaging
cable isolator bushing.
(6) Disconnect both gear shift cables ends from
transaxle shift levers (Fig. 20).
(7) Remove clutch housing vent cap, exposing the
clutch cable end and clutch release lever. Then
remove clutch cable from transaxle bellhousing (Fig.
21) (Fig. 22).
(8) Remove shift cable mounting bracket (Fig. 23).
(9) Remove Accelerator cable shield (if equipped).
(10) Remove intake manifold support bracket (if
equipped) and upper starter bolt.
(11) Remove upper bellhousing bolts.
(12) Install engine bridge fixture and support
engine.
(13) Lift vehicle on hoist and remove front wheels.
(14) Drain fluid from transaxle.
(15) Remove both front driveshafts. Refer to Group
2, Suspension for procedure.CAUTION: When reinstalling driveshafts, new drive-
shaft retaining clips must be used. Do not reuse old
clips. Failure to use new clips may result in disen-
gagement of inner constant-velocity joint.
(16) Remove power hop damper and bracket.
(17) Remove lower starter bolt (Fig. 24).
(18) Remove transaxle to rear lateral bending
strut from engine and transaxle (Fig. 25).
(19) Support transaxle with a transmission jack.
(20) Remove front motor mount through-bolt.
Remove front motor mount bolts from engine and
transaxle.
(21) Remove lower dust±shield screw and dust
shield.
Fig. 20 Shift Cables
Fig. 21 Pull Clutch Cable Backward
Fig. 22 Remove Clutch Cable From Lever
Fig. 23 Linkage Bracket Bolts
PLTRANSAXLE 21 - 9
REMOVAL AND INSTALLATION (Continued)