2000 DODGE NEON Service Repair Manual

(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 44).(25) Remove transaxle from vehicle (Fig. 44).
(26) If installing a new or replacement transaxle,
remove the upper mount as shown in (Fig. 45), trans-
fer to the replacement unit and torque all bolts to 68
N´m (50 ft. lbs.) torque.
INSTALLATION
(1) Install clutch module onto input shaft. Install
transaxle into position.
(2) Install transaxle-to-engine mounting bolts (Fig.
44) and tighten to 95 N´m (70 ft. lbs.) torque.
(3) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (80 ft. lbs.) torque (Fig. 43).
(4) Remove screwjack.
(5) Install drive plate-to-clutch module bolts and
torque to 88 N´m (65 ft. lbs.) torque.
(6) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 42).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 40).
(9) Install left engine-to-transaxle bending brace
(Fig. 40).
(10) Install structural collar (Fig. 40) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(11) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 41).
(12) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(13) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(14) Lower vehicle.
(15) Connect vehicle speed sensor connector (Fig.
39).
(16) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 38).
(17) Connect clutch cable to fork and secure to
transaxle (Fig. 37).
(18) Install bellhousing cap (Fig. 37).
(19) Connect back-up lamp switch connector.
(20) Connect ground strap to transaxle upper
mount bracket.
(21) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
Fig. 42 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 43 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 16 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(22) Install the air cleaner/throttle body assy. as
follows:
(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(23) Connect the battery cables.
(24) Road test vehicle and inspect for leaks.
Fig. 44 Transaxle Removal/Installation
1 ± MODULAR CLUTCH ASSEMBLY
2 ± CLIP3 ± TRANSAXLE
4 ± CLUTCH MODULE BOLT (4)
Fig. 45 Transaxle Upper Mount and Bracket
1 ± MOUNT
2 ± TRANSAXLE
PLTRANSAXLE 21 - 17
REMOVAL AND INSTALLATION (Continued)

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 possible.
Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench.
(2) Remove the clutch release bearing and fork.
Move the release fork and bearing to an in-line posi-
tion. Grasp the release lever with two hands in the
pivot stud socket area. Pull with even pressure to
release the fork from the pivot stud.
CAUTION: Do not use a screwdriver or pry bar to
release the fork as this may cause damage to the
fork and/or clip.
(3) Remove shift levers by driving out the roll pins.
(4) Remove transaxle case half bolts (Fig. 46).
(5) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 47). Separate
the case halves (Fig. 48).
Fig. 46 Case Bolts
1 ± CASE BOLTS
Fig. 47 Transaxle Case Halves
1 ± BELLHOUSING HALF
2 ± GEAR CASE HALF
Fig. 48 Separate Case Halves
1±PRYTOOL
2 ± CASE HALVES
3 ± PRY SLOT
21 - 18 TRANSAXLEPL

(6) Remove bellhousing half from gear case half
(Fig. 49).
(7) Remove output shaft roller bearing from output
shaft.
(8) Remove differential assembly (Fig. 50).(9) Remove reverse idler shaft bolt (Fig. 51).
(10) Remove reverse idler shaft (Fig. 52).
Fig. 49 Bellhousing Case Half Removal
1 ± BELLHOUSING CASE HALF
2 ± DIFFERENTIAL
3 ± GEAR CASE HALF
Fig. 50 Differential Assembly Removal
1 ± INPUT SHAFT
2 ± OUTPUT SHAFT
3 ± DIFFERENTIAL
4 ± CASE
Fig. 51 Reverse Idler Shaft Bolt Removal
1 ± CASE
2 ± REVERSE IDLER SHAFT
3 ± REVERSE IDLER SHAFT BOLT
Fig. 52 Reverse Idler Shaft Removal
1 ± REVERSE IDLER SHAFT
PLTRANSAXLE 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Remove reverse idler gear and spacer (Fig.
53).
(12) Remove two screws retaining reverse fork
bracket (Fig. 54). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 55).(13) Using snap±ring pliers, remove selector shaft
spacer (Fig. 56).
(14) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 57).
Fig. 53 Reverse Idler Gear and Spacer Removal
1 ± SPACER
2 ± REVERSE IDLER GEAR
Fig. 54 Screws Retaining Reverse Fork Bracket
1 ± SCREWS (2)
2 ± REVERSE FORK BRACKET
Fig. 55 Remove Reverse Fork Bracket
1 ± REVERSE FORK BRACKET
2 ± REVERSE CAM BLOCKOUT
3 ± SHIFT BLOCKER ASSEMBLY
Fig. 56 Remove Selector Shaft Spacer
1 ± SHIFT BLOCKER ASSEMBLY
2 ± SELECTOR SHAFT SPACER (PLASTIC)
3 ± SNAP RING PLIERS
21 - 20 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(15) Remove transaxle end cover (Fig. 58) (Fig.
59).(16) Remove two snap rings retaining the output
shaft and the input shaft to the bearings (Fig. 60).
Fig. 57 Selector Shaft
1 ± SHIFT ASSEMBLY
2 ± SELECTOR SHAFT
Fig. 58 Transaxle Cover Removal
1 ± TRANSAXLE CASE
2 ± END COVER
Fig. 59 End Cover
1 ± END COVER
2 ± CASE
Fig. 60 Snap Rings Retaining Bearings
1 ± SNAP RING PLIERS
2 ± SNAP RINGS
PLTRANSAXLE 21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)

(17) Using bench fixture and shims provided (Mill-
er tools # 6785, 6785-1, and 6785-2), turn transaxle
over. Install transaxle onto bench fixture (Fig. 61).
Verify shim spacers are in position on bench fixture.
Install transaxle into shop press.
(18) Install bearing fixture Miller tool #6768 onto
transaxle end bearings (Fig. 62). 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.(19) Install transaxle gear case into shop press.
Press output and input shaft assemblies out of case
(Fig. 63).
(20) Remove transaxle from press.
(21) Carefully remove transaxle case from the
shaft assemblies and bench fixture (Fig. 64). Be sure
the oil±feed trough to the end bearings is not dam-
aged (Fig. 65).
Fig. 61 Bench Fixture
1 ± SHIMS
2 ± TRANSAXLE
3 ± 6785 BENCH FIXTURE
Fig. 62 Bearing Fixture
1 ± BEARING FIXTURE
2 ± TRANSAXLE CASE
Fig. 63 Pressing Gears Out of Case
1 ± BEARING FIXTURE
2 ± PRESS RAM
3 ± TRANSAXLE CASE
4 ± BENCH FIXTURE
Fig. 64 Transaxle Case Removal
1 ± TRANSAXLE CASE
2 ± BENCH FIXTURE
3 ± GEARTRAIN
21 - 22 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(22)TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim,
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 66) (Fig. 67) (Fig. 68)
(Fig. 69) (Fig. 70).TRANSAXLE W/O REVERSE
BRAKE:Remove plastic spacer from the input shaft
assembly.
Fig. 65 Oil Feed Trough
1 ± OIL FEED TROUGH
Fig. 66 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 67 Reverse Brake Friction Cone
1 ± REVERSE BRAKE FRICTION CONE
Fig. 68 Reverse Brake Blocking Ring
1 ± REVERSE BRAKE BLOCKING RING
Fig. 69 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)