1999 DODGE NEON boot

SPARK PLUG CABLE SERVICE
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
REMOVAL
Remove spark plug cable from coil frist.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube.The connect the
other end to coil pack. OnSOHCengines, be sure
that dual plastic clip holds #1,#2 cables off of valve
cover and that PCV hose plastic clip holds #3 cable
away from metal PCV clamp and edge of air duct. On
DOHC, be sure that the plastic clip on PCV hose is
positioned so that cable clip is beneath hose, and that
#1 cable is snapped into this clip to protect it from
metal PCV clamp.
SPARK PLUG TUBES
The spark plugs tubes are pressed into the cylinder
head. Sealant is applied to the end of the tube before
installation. For engine information, refer to Group
9, Engines.
IGNITION COIL
SOHC/DOHC
The electronic ignition coil pack attaches directly
to the valve cover (Fig. 29) or (Fig. 30).
REMOVAL
(1) Disconnect electrical connector from coil pack.
(2) Remove coil pack mounting nuts.
(3) Remove coil pack.
INSTALLATION
(1) Install coil pack on valve cover.
(2) Transfer spark plug cables to new coil pack.
The coil pack towers are numbered with the cylinder
identification. Be sure the ignition cables snap onto
the towers.
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 31). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.CAMSHAFT POSITION SENSORÐSOHC
The camshaft position sensor is mounted to the
rear of the cylinder head (Fig. 32).
REMOVAL
(1) Disconnect the filtered air tube from the throt-
tle body and air cleaner housing. Remove filtered air
tube.
Fig. 29 Electronic Ignition Coil PackÐSOHC
Fig. 30 Electronic Ignition Coil PackÐDOHC
Fig. 31 Power Distribution Center (PDC)
PLIGNITION SYSTEM 8D - 13
REMOVAL AND INSTALLATION (Continued)

the panel rearward to disengage the three locator
pins and remove.
(6) Reach in and disconnect the wiring connector(s)
for the rear window defogger and/or fog lamp
switch(s) as required.
INSTALLATION
For installation, reverse the above procedures.
SHIFTER KNOB
AUTOMATIC TRANSMISSION SHIFTER
REMOVAL
(1) Loosen the set screw at the left side under the
button area.
(2) Pull up until the knob slides off the shifter
shaft.
INSTALLATION
For installation, reverse the above procedures.
MANUAL TRANSMISSION SHIFTER
REMOVAL
(1) Pull the top part of the boot down until the two
tabs at the bottom of the knob are exposed.
(2) Release the locking tabs from the pins on the
shifter shaft.
(3) Pull up until the knob slides off the shifter
shaft.INSTALLATION
For installation, reverse the above procedures.
STEERING COLUMN COVER
REMOVAL
(1) Remove the three attachment screws along the
bottom of the cover and screw on the left outward
face of cover (Fig. 24).
(2) Grasp the cover and pull rearward until the
clips disengage.
INSTALLATION
For installation, reverse the above procedures.
STEERING COLUMN COVER LINER
REMOVAL
(1) Remove the steering column cover (Fig. 19).
(2) Remove the two attachment screws at the
upper area of the liner and the lower left corner.
INSTALLATION
For installation, reverse the above procedures.
STEERING COLUMN SHROUDS
(1) Remove the steering column cover and steering
column cover liner.
Fig. 24 Instrument Panel and Top Cover
PLINSTRUMENT PANEL AND SYSTEMS 8E - 13
REMOVAL AND INSTALLATION (Continued)

LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CITYLIGHT LAMP BULB.................... 3
FOG LAMP BULB......................... 3FRONT TURN SIGNAL LAMP BULB........... 2
HEADLAMP BULB........................ 2
SIDE REPEATER LAMP BULB............... 4
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Disengage wire connector to headlamp bulb.
(3) Remove headlamp assembly from vehicle.
(4) Remove rubber seal boot (Fig. 1).
(5) Disengage retaining ring from headlamp (Fig.
2).
(6) Pull headlamp bulb from back of headlamp
assembly (Fig. 3).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers of other possibly oily surface. Reduced
bulb life will result.
(1) Insert headlamp bulb to headlamp assembly.
(2) Install retaining ring to headlamp assembly.
(3) Install rubber seal boot.
(4) Engage wire connector to headlamp bulb base.
(5) Install headlamp assembly into vehicle.
(6) Verify headlamp alignment.
FRONT TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove screws holding the park and turn sig-
nal lamp to the headlamp assembly.
(2) Separate the turn signal lamp from the head-
lamp module.
(3) Rotate front turn signal lamp socket one quar-
ter turn counter-clockwise.
(4) Pull socket from back of lamp.
Fig. 1 Rubber Boot Seal
Fig. 2 Headlamp Bulb Retaining Ring
Fig. 3 Headlamp Bulb
8L - 2 LAMPSPL

(3) Connect Bulb Power Lead to Harness
(4) Compress Wire Bulb Retainer and engage into
lock tabs on fog lamp housing
(5) Install Fog Lamp Housing into Fog Lamp
Bracket.(6) Install Fog Lamp Assembly into fascia.
SIDE REPEATER LAMP BULB
REMOVAL
(1) Push lamp rearward.
(2) While pushing lamp, pry forward edge of lamp
away from car
(3) Pull lamp from hole
(4) Pull rubber boot away from lamp housing.
(5) Rotate and pull bulb from socket
INSTALLATION
(1) Align side repeater lamp bulb to socket
(2) Push and twist bulb into socket.
(3) Push rubber boot over lamp housing.
(4) Position side repeater lamp assembly to hole in
fender.
NOTE: The metal clip should be opposite of notch
in fender hole.
(5) Compress metal clip by pushing lamp rearward
(6) While pushing lamp assembly rearward, push
lamp into fender hole.
(7) Ensure that lamp is firmly attatched to body.
Fig. 8 Bulb Power and Ground Leads
8L - 4 LAMPSPL
REMOVAL AND INSTALLATION (Continued)

(13) Start the engine and let run for a few seconds.
Then turn the engine off.
(14) Add fluid if necessary.
(15) Raise front wheels of vehicle off the ground.
(16) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks.Fill pump reservoir to correct
level with Mopart, Power Steering Fluid, or
equivalent.See Checking Fluid Level.
(17) Lower front wheels of vehicle back on the
ground.
CAUTION: During this procedure do not allow the
steering gear inner tie rod boots to become twisted.
(See Wheel Alignment in the suspension section of
this service manual).
(18) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
(19) Tighten tie rod jam nut (Fig. 18) to 61 N´m
(45 ft.lbs.) torque.
(20) Adjust steering gear to tie rod boots at tie
rods.
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD
DISASSEMBLE
(1) Loosen the inner tie rod to outer tie rod jam
nut (Fig. 19). Thread the jam nut far enough up the
inner tie rod to pull the collar (Fig. 19) away fromthe outer tie rod end. Pull the collar off the end of
the outer tie rod.
(2) Remove the nut attaching the outer tie rod end
to steering knuckle (Fig. 20).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(3) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 21) .
(4) Remove outer tie rod from inner tie rod by un-
threading it from the inner tie rod.
ASSEMBLE
(1) Install the jam nut (Fig. 19) on inner tie rod
end.
Fig. 18 Outer Tie Rod End Jam Nut
Fig. 19 Outer Tie Rod
Fig. 20 Removing /Installing Tie Rod End Attaching
Nut
19 - 32 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

NOTE: Be sure the collar is installed on the inner
tie rod with the flat end of the collar against jam nut
and the open end of the collar facing the outer tie
rod end.
(2) Install the collar (Fig. 19) on the inner tie rod.
(3) Install outer tie rod onto inner tie rod (Fig. 19).
(4) Position the collar around the end of the outer
tie rod (Fig. 19).
(5) Thread the jam nut down the inner tie far
enough to hold the collar in place on the outer tie
rod. Do not tighten jam nut.
(6) Install the tie rod end into the steering
knuckle. Start tie rod end to steering knuckle attach-
ing nut onto stud of tie rod end. While holding stud
of tie rod end stationary, tighten tie rod end to steer-
ing knuckle attaching nut (Fig. 20). Then using a
crowfoot and 11/32 socket (Fig. 22), torque the tie rod
end attaching nut to 61 N´m (45 ft. lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See WheelAlignment in the suspension section of this service
manual).
(7) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
CAUTION: Prior to tightening the jam nut to the
specified torque, check the orientation of the collar
to be sure it is in the proper position to fit up
against the outer tie rod end.
(8) Torque the tie rod jam nut (Fig. 19) to a torque
of 55 N´m (40 ft. lbs.) torque.
(9) Adjust the steering gear to inner tie rod boots
at inner tie rod if they became twisted during Toe
adjustment.
Fig. 22 Torquing Tie Rod End Attaching NutFig. 21 Tie Rod End Removal From Steering
Knuckle
PLSTEERING 19 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

TRANSAXLE
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE............. 40 NVT350 (A-578) MANUAL TRANSAXLE....... 1
NV T350 (A-578) MANUAL TRANSAXLE
INDEX
page page
GENERAL INFORMATION
GEAR RATIOS........................... 2
GEARSHIFT PATTERN..................... 2
NV T350 MANUAL TRANSAXLE.............. 1
SEALANTS.............................. 2
SELECTION OF LUBRICANT................ 2
SPECIAL ADDITIVES...................... 2
TRANSAXLE IDENTIFICATION INFORMATION . . . 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
SHIFT LEVERS.......................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS...................... 3
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 3
LOW LUBRICANT LEVEL................... 3
NOISY OPERATION....................... 3
SLIPS OUT OF GEAR..................... 3
SERVICE PROCEDURES
FLUID DRAIN AND FILL.................... 3
REMOVAL AND INSTALLATION
AXLE SEALS............................ 8
BACK-UP LAMP SWITCH................... 7
CROSSOVER LEVER...................... 7
GEARSHIFT BOOT....................... 4
GEARSHIFT CABLES...................... 4GEARSHIFT KNOB....................... 4
GEARSHIFT MECHANISM REPLACEMENT..... 6
SELECTOR LEVER....................... 8
SHIFT SHAFT SEALS...................... 8
TRANSAXLE............................ 8
VEHICLE SPEED SENSOR DRIVE GEAR...... 7
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 24
INPUT SHAFT.......................... 20
OUTPUT SHAFT........................ 24
SHIFT RAILS OVERHAUL................. 29
SYNCHRONIZER........................ 29
TRANSAXLE CASE OVERHAUL............. 30
TRANSAXLE........................... 10
CLEANING AND INSPECTION
SYNCHRONIZER........................ 35
TRANSAXLE........................... 35
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 35
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT......................... 36
GEARSHIFT CROSSOVER CABLE........... 35
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS.......... 37
SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE....... 37
GENERAL INFORMATION
NV T350 MANUAL TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This five speed is a constant-mesh manual tran-
saxle. All gear ranges, except reverse, are synchro-
nized. The reverse gear utilizes a brake and blockingring for shifting ease. The reverse idler gear is sup-
ported on a sliding spindle idler shaft. The transaxle
case is aluminum with a steel end±plate bearing
cover. It is housed in a die-cast aluminum case fea-
turing a two±piece, middle split design.
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
PLTRANSAXLE 21 - 1

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)