1999 DODGE NEON Service Repair Manual

CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N´m (60 ft. lbs.) torque.
SPEEDOMETER DRIVE GEAR
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
REMOVAL
(1) Pry the plastic speedometer drive gear off of
the differential case using a flat blade pry tool (Fig.
100) (Fig. 101).
INSTALLATION
NOTE: A new speedometer drive gear must be
installed on differential assembly. The lip on the
speedometer drive gear must be positioned down-
ward when installing onto differential assembly.(1) Position speedometer drive gear onto differen-
tial assembly (Fig. 102).
(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
103) (Fig. 104). Do not use a hammer.
DIFFERENTIAL GEARS
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears. Refer to Speedometer
Drive Gear for service information.
Fig. 100 Pry Off Speedometer Drive Gear
Fig. 101 Speedometer Drive Gear Removed
Fig. 102 Speedometer Drive Gear
Fig. 103 Press Gear onto Diferential
21 - 26 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 105)
(Fig. 106).
(2) Remove pinion shaft (Fig. 107).(3) Rotate side gears to opening in differential
(Fig. 108).
(4) Remove differential gears (Fig. 109).
Fig. 104 Drive Gear Pressed onto Differential
Fig. 105 Remove Pinion Shaft Retaining Pin
Fig. 106 Retaining Pin Removed
Fig. 107 Pinion Shaft Removal
Fig. 108 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in Case
PLTRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 110).
(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 111).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise.
(5) Set up dial indicator as shown and record end
play (Fig. 112) (Fig. 113). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear
90 degrees and record a final end play.
(6) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. Theother side gear should be checked using the same
procedure.
CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(7) After the end play is measured and adjusted,
replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
tion, refer to Speedometer Drive Gear service in this
section.
Fig. 109 Differential Gears
Fig. 110 Install Retaining Pin
Fig. 111 Staking Retaining Pin
21 - 28 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with theU
facing upward.
(2) Install springs into hub slot (Fig. 114).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 115).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 116).
(6) Line up stop ring tang over the keys in the hub
(Fig. 117). Install stop rings. Center the keys and
balls by pushing on both stop rings.
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.
Fig. 112 Checking Side Gear End Play (Typical)
Fig. 113 Checking Side Gear End Play (Typical)
Fig. 114 Synchronizer Assembly
Fig. 115 Synchronizer Balls
Fig. 116 Synchronizer Sleeve
PLTRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

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
²Output bearing race and retainer
²Input bearing and sleeve
²Differential bearing cones
²Shift rail bushings
²Shift shafts
²Shift shaft seals
²Shift shaft bushings
²Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
(1) Insert a flat±blade pry tool at outer edge of
axle shaft seal (Fig. 118).
(2) 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 with C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position (Fig. 119).
OUTPUT BEARING
REMOVAL
NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end±to±end.
Install bearing with larger diameter cage ring facing
out.
Fig. 117 Keys in HubFig. 118 Axle Shaft Seal Removal
Fig. 119 Axle Seal Installation
21 - 30 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Remove caged roller bearing from output bear-
ing race (Fig. 120).
(2) Remove screws at output bearing retainer
strap (Fig. 121).
(3) Install tool #6787 and slide hammer (Fig. 122).
Tighten tool to output bearing race.
(4) Using slide hammer, remove output bearing
race.
INSTALLATION
(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-
ing race (Fig. 123). Tap race into bore. Install output
bearing into race. Verify that the larger diameter
cage is facing outward. Position bearing retaining
strap. Tighten bolts to 11 N´m (96 in. lbs.).
INPUT BEARING AND SLEEVE
The input bearing is a one±piece bearing and
sleeve unit (Fig. 124). The sleeve is the slide point for
the clutch±release bearing and lever.
Fig. 123 Output Bearing Race Installation
Fig. 120 Output Roller Bearing
Fig. 121 Output Bearing Strap
Fig. 122 Output Bearing Race Removal
PLTRANSAXLE 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)

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.
125).
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.
126).
(3) Using the spacer tool #4894 and shop press,
install input bearing into bore until it is fully seated
(Fig. 127).
DIFFERENTIAL BEARING CUPS
REMOVAL
(1) Remove differential assembly from gear case
using the procedure outlined in this group.(2) Install Miller tool #L-4518 into the differential
bearing cup (Fig. 128).
(3) Install the tool cup over the tool (Fig. 129).
Fig. 124 Input Bearing And Sleeve
Fig. 125 Input Bearing Removal
Fig. 126 Input Bearing Tool
Fig. 127 Input Bearing Installed
Fig. 128 Tool Installed in Bearing
21 - 32 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Tighten the tool until the race is removed from
the case.
INSTALLATION
(1) Position the bearing cup into the case.
(2) Install the bearing cup onto Miller tool
#L-4520.
(3) Using Miller tool #L-4520 and C-4171 driver,
install differential bearing cup into the transaxle
case.
SHIFT RAIL BUSHINGS
REMOVAL
(1) Thread tool #6786 into shift rail bushing.
(2) Install slide hammer #3752 onto tool.
(3) Remove bushing using slide hammer and tool
assembly (Fig. 130).
INSTALLATION
(1) Line up replacement bushing in bore.(2) Using tool #MD998343, tap bushing into bore
until flush with the chamfer in the case.
SHIFT SHAFT SEALS
It is not necessary 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.
SHIFT SELECTOR SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
selector shaft by pushing on the shaft from the out-
side. Pull shaft out from the inside.
INSTALLATION
(1) Reverse removal procedure to install selector
shaft.
SHIFT CROSSOVER SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
crossover shaft seal.
(3) Using snap±ring pliers, remove the snap ring
at the crossover shaft bore (Fig. 131).
Fig. 129 Tool Cup Installed
Fig. 130 Shift Rail Bushing Removal
Fig. 131 Crossover Shaft Snap Ring
PLTRANSAXLE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)