1999 DODGE NEON Service Repair Manual

ASSEMBLY
When rebuilding, reverse the above procedure.
VALVE BODY RECONDITION
NOTE: Tighten all valve body screws to 5 N´m (40
in. lbs.)
Do not clamp any portion of valve body or transfer
plate in a vise. Any slight distortion of the aluminum
body or transfer plate will result in sticking valves,
excessive leakage, or both.When removing or
installing valves or plugs, slide them in or out
carefully. Do not use force.
NOTE: TAG ALL SPRINGS AS THEY ARE
REMOVED FOR REASSEMBLY IDENTIFICATION.
Fig. 69 Detent Spring Attaching Screw and Spring
Fig. 70 Using Tool L-4553 on Valve Body Screw
Fig. 71 Remove or Install Valve Body Screws
Fig. 72 Transfer Plate and Separator Plate
Fig. 73 Steel Ball Locations
21 - 74 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 74 Remove or Install Throttle Shaft E-Clip
Fig. 75 Throttle Shaft E-Clip, Washer, and Seal
Fig. 76 Manual Valve Lever Assembly
Fig. 77 Throttle Valve Lever Assembly
Fig. 78 Manual Valve
Fig. 79 Pressure Regulator and Adjusting Screw
Bracket
PLTRANSAXLE 21 - 75
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 80 Pressure Regulators and Manual Controls
Fig. 81 Governor Plugs
21 - 76 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 82 Pressure Regulator Valve Plugs
Fig. 83 Shift Valves and Shuttle Valve
PLTRANSAXLE 21 - 77
DISASSEMBLY AND ASSEMBLY (Continued)

OIL PUMP-RECONDITION
NOTE: Also, check gear side clearance with a
straight edge and a feeler gauge (See Specifica-tions).
FRONT CLUTCH-RECONDITION
DISASSEMBLY
Fig. 84 Reaction Shaft Support Bolts
Fig. 85 Reaction Shaft Support
Fig. 86 Inner and Outer Pump Gears
Fig. 87 Measuring Pump Clearance (Gear to Pocket)
Fig. 88 Front Clutch Waved Snap Ring
21 - 78 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
To reassemble, reverse the above procedure.MEASURING PLATE CLEARANCE
REAR CLUTCH-RECONDITION
INSPECTION
Inspect facing material on all driving discs.
Replace discs that are charred, glazed, or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off, or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate and pres-
sure plate surface for burning, scoring, or damaged
driving lugs. Replace if necessary. Inspect plates and
discs for flatness; they must not be warped or cone-
shaped.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces; plates must travel freely in the
grooves. Note ball check in piston; be sure ball moves
freely. Inspect seal rings surfaces in clutch retainer
for nicks or deep scratches; light scratches will not
interfere with sealing of the seals. Inspect Neoprene
seal rings for deterioration, wear, and hardness.
Fig. 89 Thick Steel Plate and Waved Snap Ring
Fig. 90 Front Clutch (4-Disc Shown)
Fig. 91 Front Clutch Return Spring Snap Ring
Fig. 92 Front Clutch Return Spring and Piston
Fig. 93 Measuring Front Clutch Plate Clearance
PLTRANSAXLE 21 - 79
DISASSEMBLY AND ASSEMBLY (Continued)

Inspect piston spring and waved snap ring for distor-
tion or breakage.
Inspect Teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
0.061 to 0.063 inch. Replace if necessary.
DISASSEMBLY
Fig. 94 Rear Clutch Outer Snap Ring
Fig. 95 Rear Clutch (4-Disc Shown)
Fig. 96 Piston Spring Waved Snap Ring
Fig. 97 Rear Clutch Piston and Piston Spring
Fig. 98 Remove or Install Input Shaft Snap Ring
21 - 80 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Press out input shaft, if required.
ASSEMBLY
To reassemble, reverse the above procedure.
MEASURING PLATE CLEARANCE
FRONT PLANETARY AND ANNULUS GEAR-
RECONDITION
Fig. 99 Input Shaft Snap Ring
Fig. 100 Measuring Rear Clutch Plate Clearance
Fig. 101 Front Planetary Gear Snap Ring and No. 4
Thrust Washer (Always Install a New Snap Ring)
Fig. 102 Front Planetary Gear
Fig. 103 Annulus Gear Support Front Snap Ring
PLTRANSAXLE 21 - 81
DISASSEMBLY AND ASSEMBLY (Continued)