1999 DODGE NEON Service Repair Manual

(4) Push the crossover shaft in the case and
remove the crossover assembly.
INSTALLATION
(1) Reverse removal procedure to install crossover
shaft.
SHIFT SELECTOR SHAFT BUSHING
REMOVAL
(1) Remove selector shaft using procedure in this
group.
(2) Thread tool #6786 into bushing.
(3) Install slide hammer #3752 onto tool and
remove bushing using slide hammer (Fig. 132).
INSTALLATION
(1) Position replacement bushing over selector
shaft bore.
(2) Using an appropriate size deep±well socket,
install bushing in selector shaft bore (Fig. 133).
SHIFT CROSSOVER SHAFT BUSHING
REMOVAL
(1) Install slide hammer #3752 through the cross-
over bushing.
(2) Thread nut and washer onto slide hammer.
(3) Using the slide hammer, remove the crossover
shaft bushing (Fig. 134).
INSTALLATION
(1) Position the replacement crossover shaft bush-
ing over the crossover shaft bushing bore.
(2) Using an appropriate size deep±well socket,
install the crossover shaft bushing into the bushing
bore.
REAR BEARING OIL FEED TROUGH
The bearing oil feed trough is retained in the case
by a pin that is molded into the case and clips that
are part of the trough (Fig. 135).
Fig. 132 Selector Shaft Bushing Removal
Fig. 133 Selector Shaft Bushing Installation
Fig. 134 Crossover Shaft Bushing Removal
Fig. 135 Oil Feed Trough
21 - 34 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro keys and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 136).(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. 137). 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.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
Fig. 136 Crossover Cable Adjustment Screw
Fig. 137 Crossover Lever Pin Procedure
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings, if one input shaft bearing is defective, replace
both input shaft bearings.
(5) Bearing cones must not be reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction.
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. 138).
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 inStep 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. 139).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.
Fig. 138 Checking Differential Bearing End Play to
Determine Shim Thickness
Fig. 139 Checking Differential Bearing Turning
Torque
21 - 36 TRANSAXLEPL
ADJUSTMENTS (Continued)

SPECIFICATIONS
NV T350 (A-578)
DESCRIPTION TORQUE
Back-up Lamp Switch..........24N´m(18ft.lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug.................30N´m(267 in. lbs.)
Differential Ring Gear Bolts.....81N´m(60ft.lbs.)
Dust Shield to Transaxle......12N´m(105 in. lbs.)
End Plate Cover Bolts.........29N´m(21ft.lbs.)
Front Engine Mount to Trans . . .108 N´m (80 ft. lbs.)
Front Mount Through Bolt......61N´m(45ft.lbs.)
Front Mount to Engine Bolt.....54N´m(40ft.lbs.)
Lateral Bending
Strut to Engine.............54N´m(40ft.lbs.)
Lateral Bending Strut to Trans. . .54 N´m (40 ft. lbs.)
Left Mount Through Bolt......108 N´m (80 ft. lbs.)
Left Mount to Transaxle........54N´m(40ft.lbs.)
Output Bearing Race Ret. Strap .11 N´m (96 in. lbs.)
Power Hop Damper Bkt. to
Trans.....................54N´m(40ft.lbs.)
Power Hop Damper to
Frame Bkt.................54N´m(40ft.lbs.)
Power Hop Damper to
Trans. Bkt.................54N´m(40ft.lbs.)
Reverse Fork Bracket..........11N´m(96in.lbs.)
Reverse Idler Shaft Bolt........26N´m(19ft.lbs.)
Shift Cable Bracket to
Transaxle................28N´m(250 in. lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Transaxle to Engine Bolt.......95N´m(70ft.lbs.)
Trans. to Eng. Intake Bkt. Bolts . .95 N´m (70 ft. lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vertical Bending Strut to
Engine..................108 N´m (80 ft. lbs.)
Vertical Bending Strut to Trans. .108 N´m (80 ft. lbs.)
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
SPECIAL TOOLS
SPECIAL TOOLS±NV T350 (A-578) MANUAL
TRANSAXLE
NV T350 (A-578) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
NV T350 1.9-2.2 Liters 2.0-2.3 Quarts
Adapter Blocks C-293±45
Puller Press C-293±PA
Dial Indicator C-3339
Sleeve C-3717
PLTRANSAXLE 21 - 37

Slide Hammer C-3752
Universal Handle C-4171
Bearing Installer C-4628
Seal Remover C-4680
Seal Installer C-4992
Torque Tool C-4995
Adapter C-4996
Installer L-4410
21 - 38 TRANSAXLEPL
SPECIAL TOOLS (Continued)

Special Jaw Set L-4518
Bearing Splitter 1130
Driver 6342
Seal Installer 6709
Bearing Remover 6768
Bench Fixture 6785
Remover 6786
Remover 6787
PLTRANSAXLE 21 - 39
SPECIAL TOOLS (Continued)

31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
FLUID LEVEL AND CONDITION............. 41
GENERAL INFORMATION................. 40
SELECTION OF LUBRICANT............... 41
SPECIAL ADDITIVES..................... 41
DESCRIPTION AND OPERATION
AUTOMATIC TRANSMISSION SHIFTER/
IGNITION INTERLOCK.................. 42
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR....................... 42
FLOW CONTROL VALVES................. 42
GEARSHIFT AND PARKING LOCK CONTROLS . 42
GOVERNOR............................ 43
HYDRAULIC CONTROL SYSTEM............ 42
PRESSURE REGULATING VALVES.......... 42
PRESSURE SUPPLY SYSTEM.............. 42
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR.................. 43
TORQUE CONVERTER CLUTCH............ 42
DIAGNOSIS AND TESTING
CLUTCH AND SERVO AIR PRESSURE TESTS . 54
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA............ 55
HYDRAULIC PRESSURE TESTS............ 52
INTERLOCK SYSTEM OPERATION CHECK.... 55
ROAD TEST............................ 52
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS.............................. 43
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR.............. 58
FLUID AND FILTER CHANGE............... 56
FLUID DRAIN AND REFILL................. 57
FLUSHING COOLERS AND TUBES.......... 58
OIL PUMP VOLUME CHECK............... 58
REMOVAL AND INSTALLATION
GEARSHIFT CABLE...................... 59
GEARSHIFT MECHANISM................. 60
INTERLOCK MECHANISM................. 63
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH........................ 64
PUMP OIL SEAL......................... 67
SHIFTER IGNITION INTERLOCK CABLE...... 61THROTTLE PRESSURE CABLE............. 60
TRANSAXLE........................... 64
VEHICLE SPEED SENSOR PINION GEAR..... 64
DISASSEMBLY AND ASSEMBLY
ACCUMULATOR-RECONDITION............ 83
DIFFERENTIAL REPAIR................... 95
FRONT CLUTCH-RECONDITION............ 78
FRONT PLANETARY AND ANNULUS GEAR-
RECONDITION........................ 81
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................ 83
LOW/REVERSE (REAR)
SERVO-RECONDITION.................. 82
OIL PUMP-RECONDITION................. 78
OUTPUT SHAFT REPAIR.................. 89
PARKING PAWL......................... 89
REAR CLUTCH-RECONDITION............. 79
TRANSAXLE........................... 67
TRANSFER SHAFT REPAIR................ 83
VALVE BODY RECONDITION............... 74
CLEANING AND INSPECTION
VALVE BODY........................... 99
ADJUSTMENTS
BAND ADJUSTMENT.................... 101
BEARING ADJUSTMENT PROCEDURES..... 101
DIFFERENTIAL BEARING................. 102
GEARSHIFT CABLE...................... 99
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS....................... 101
OUTPUT SHAFT BEARING................ 102
SHIFTER/IGNITION INTERLOCK SYSTEM.... 100
THROTTLE PRESSURE CABLE ADJUSTMENT
PROCEDURE........................ 100
TRANSFER SHAFT BEARING............. 103
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . 105
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE............ 113
31TH TRANSAXLE TORQUE
SPECIFICATIONS..................... 113
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE............ 114
GENERAL INFORMATION
GENERAL INFORMATION
NOTE: Safety goggles should be worn at all times
when working on these transaxles.This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
21 - 40 TRANSAXLEPL

NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
fluid through a remote cooler. There are two types of
coolers used. An oil-to-water type cooler located in
the radiator side tank and/or an oil-to-air heat
exchanger. The torque converter assembly is a sealed
unit that cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.
Engine torque is transmitted to the torque con-
verter and then through the input shaft to multiple-
disc clutches in the transaxle. The power flow
depends on the application of the clutches and bands.
Refer to Elements in Use Chart in Diagnosis and
Tests section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The driving shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor in the
transaxle final drive (axle) ratio. The shaft also car-
ries the governor and parking sprag. An integral heli-cal gear on the transfer shaft drives the differential
ring gear. The final drive gearing is completed with
one of two gear ratios; 2.98 or 3.19 depending on
model and application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fills in both the P (Park) and
N (Neutral) positions. Place the selector lever in P
(Park) to be sure that the fluid level check is accu-
rate.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. This will ensure complete oil
level stabilization between differential and
transmission.The fluid should be at normal operat-
ing temperature (approximately 82É C. or 180É F.).
The fluid level is correct if it is in the HOT region
(cross-hatched area) on the dipstick.
Low fluid level can cause a variety of conditions,
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy therefore, pressures will be
low and will build up slowly.
Improper filling also can raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
that occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming also can result in fluid escaping from the
transaxle dipstick, where it may be mistaken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
or is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
these transmissions. Mopar ATF PLUS 3 (Automatic
Transmission Fluid- type 7176) should be used to aid
in ensuring optimum transmission performance. It is
important that the transmission fluid be maintained
at the prescribed level using the recommended fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transmission, other than
that fluid listed above. An exception to this policy is
PLTRANSAXLE 21 - 41
GENERAL INFORMATION (Continued)