1999 DODGE NEON Service Repair Manual

(22) Rotate engine crankshaft clockwise to expose
driveplate±to±modular clutch bolts.
NOTE: Before removal of bolts, mark the driveplate
and clutch pressure plate for ease of assembly
alignment.
(23) Remove four driveplate±to±modular clutch
bolts to separate driveplate from clutch assembly.
(24) Push modular clutch assembly into the tran-
saxle bellhousing for easier transaxle removal.
(25) Remove frame rail to left transaxle mount
through-bolt (Fig. 26).
(26) Remove left transaxle mount from transaxle.
Then push mount up to gain clearance for transaxle
removal.(27) Remove transaxle from vehicle.
(28) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
(1) To install transaxle, reverse removal procedure.
(2) After installing transaxle, fill transaxle to bot-
tom of fill plug hole (vehicle level on hoist). Fill tran-
saxle with Moparttype M.S. 9417 Manual Transaxle
Fluid before lowering vehicle to floor.
(3) Verify that vehicle's back-up lights and speed-
ometer are functioning properly. Crossover cable
adjustment procedure is required after installing
transaxle in car to ensure proper shifter adjustment.
Road test vehicle for proper transaxle function.
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 possi-
ble. Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench.
(2) Remove shift levers. Remove transaxle case
half bolts (Fig. 27).
(3) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 28). Separate
the case halves (Fig. 29).
(4) Remove bellhousing half from gear case half
(Fig. 30).
(5) Remove output shaft roller bearing from output
shaft.
Fig. 24 Starter Bolts
Fig. 25 Bracket Removal
Fig. 26 Left Transaxle Mount Through-Bolt
21 - 10 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(6) Remove differential assembly (Fig. 31).
(7) Remove reverse idler shaft bolt (Fig. 32).
Remove reverse idler gear (Fig. 33).
Fig. 27 Case Bolts
Fig. 28 Transaxle Case Halves
Fig. 29 Separate Case Halves
Fig. 30 Bellhousing Case Half Removal
Fig. 31 Differential Assembly Removal
Fig. 32 Reverse Idler Shaft Bolt Removal
PLTRANSAXLE 21 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

(8) Remove two screws retaining reverse fork
bracket (Fig. 34). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 35).(9) Using snap±ring pliers, remove selector shaft
spacer (Fig. 36).
(10) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 37).
Fig. 33 Reverse Idler Gear Removal
Fig. 34 Screws Retaining Reverse Fork Bracket
Fig. 35 Remove Reverse Fork Bracket
Fig. 36 Remove Selector Shaft Spacer
Fig. 37 Selector Shaft
21 - 12 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Remove transaxle end cover (Fig. 38) (Fig. 39).
(12) Remove two snap rings retaining the output
shaft and the input shaft to the bearings (Fig. 40).(13) Using bench fixture and shims provided (Mill-
er tools # 6785, 6785-1, and 6785-2), turn transaxle
over. Install transaxle onto bench fixture (Fig. 41).
Verify shim spacers are in position on bench fixture.
Install transaxle into shop press.
(14) Install bearing fixture Miller tool #6768 onto
transaxle end bearings (Fig. 42). Verify tool is prop-
erly aligned to input and output shafts.
CAUTION: The oil dams in the input and output
shafts can be damaged while pressing on the
shafts if the bearing fixture is not used properly.
(15) Install transaxle gear case into shop press.
Press output and input shaft assemblies out of case
(Fig. 43).
(16) Remove transaxle from press.
(17) Carefully remove transaxle case from the
shaft assemblies and bench fixture (Fig. 44). Be sure
the oil±feed trough to the end bearings is not dam-
aged (Fig. 45).
Fig. 38 Transaxle Cover Removal
Fig. 39 End Cover
Fig. 40 Snap Rings Retaining Bearings
Fig. 41 Bench Fixture
Fig. 42 Bearing Fixture
PLTRANSAXLE 21 - 13
DISASSEMBLY AND ASSEMBLY (Continued)

(18)TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim,
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 46) (Fig. 47) (Fig. 48)(Fig. 49) (Fig. 50).TRANSAXLE W/O REVERSE
BRAKE:Remove plastic spacer from the input shaft
assembly.
Fig. 43 Pressing Gears Out of Case
Fig. 44 Transaxle Case Removal
Fig. 45 Oil Feed Trough
Fig. 46 Reverse Brake Shim
Fig. 47 Reverse Brake Friction Cone
Fig. 48 Reverse Brake Blocking Ring
21 - 14 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(19) Remove the shift blocker assembly from the
bench fixture (Fig. 51).
(20) Remove the 1-2 shift fork from the output
shaft (Fig. 52).(21) Remove input and output shaft assemblies
from bench fixture (Fig. 53).
CAUTION: The output shaft assembly 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 complete output
shaft assembly.
ASSEMBLY
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.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 54).
(2) Install shift rails and forks into bench fixture
(Fig. 55).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 56).
Fig. 49 Reverse Brake Needle Bearing
Fig. 50 Reverse Brake Race
Fig. 51 Shift Blocker Removal
Fig. 52 1±2 Shift Fork Removal
Fig. 53 Gear Train Removal
PLTRANSAXLE 21 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Install reverse brake race onto input shaft (Fig.
57).
(5) Install reverse brake needle bearing (Fig. 58).
(6) Install reverse brake blocking ring (Fig. 59).
Fig. 54 Bench Fixture
Fig. 55 Shift Rail Installation
Fig. 56 Shift Blocker Installation
Fig. 57 Reverse Brake Race Installation
Fig. 58 Reverse Brake Needle Bearing
Fig. 59 Reverse Brake Blocking Ring Installation
21 - 16 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Install reverse brake friction cone (Fig. 60).
(8) Install reverse brake shim (Fig. 61). Apply
petroleum jelly to shim to hold in place.
(9) Install gear±case half over bench fixture (Fig.
62). Line up shift finger over 3-4 lug.
(10) Line up reverse brake friction cone lugs to the
slots in the gear case (Fig. 63). Verify reverse brake
shim is in position.
(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 64).
Fig. 60 Reverse Brake Friction Cone Installation
Fig. 61 Reverse Brake Shim
Fig. 62 Gear Case Half
Fig. 63 Friction Cone Lugs
Fig. 64 Installing Input and Output Bearings
PLTRANSAXLE 21 - 17
DISASSEMBLY AND ASSEMBLY (Continued)