2000 DODGE NEON Service Repair Manual

(23) Remove the shift blocker assembly from the
bench fixture (Fig. 71).
(24) Remove the 1-2 shift fork from the output
shaft (Fig. 72).
(25) Remove input and output shaft assemblies
from bench fixture (Fig. 73).CAUTION: The output shaft assembly is serviced
as an assembly. Do not try to repair any component
on the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the complete output
shaft assembly.
Fig. 70 Reverse Brake Race
1 ± REVERSE BRAKE RACE
Fig. 71 Shift Blocker Removal
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 72 1±2 Shift Fork Removal
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 73 Gear Train Removal
1 ± 6785 BENCH FIXTURE
2 ± INPUT AND OUTPUT SHAFTS
21 - 24 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
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.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 74).
(2) Install shift rails and forks into bench fixture
(Fig. 75).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 76).
(4) Install reverse brake race onto input shaft (Fig.
77).
(5) Install reverse brake needle bearing (Fig. 78).
Fig. 74 Bench Fixture
1 ± BENCH FIXTURE
2 ± GEARTRAIN
Fig. 75 Shift Rail Installation
1 ± 6785 BENCH FIXTURE
2 ± 1±2 SHIFT FORK
Fig. 76 Shift Blocker Installation
1 ± 6785 BENCH FIXTURE
2 ± SHIFT BLOCKER ASSEMBLY
Fig. 77 Reverse Brake Race Installation
1 ± REVERSE BRAKE RACE
Fig. 78 Reverse Brake Needle Bearing
1 ± REVERSE BRAKE NEEDLE BEARING
PLTRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(6) Install reverse brake blocking ring (Fig. 79).
(7) Install reverse brake friction cone (Fig. 80).(8) Install reverse brake shim (Fig. 81). Apply
petroleum jelly to shim to hold in place.
(9) Install gear±case half over bench fixture (Fig.
82). Line up shift finger over 3-4 lug.
Fig. 79 Reverse Brake Blocking Ring Installation
1 ± REVERSE BRAKE BLOCKING RING
Fig. 80 Reverse Brake Friction Cone Installation
1 ± REVERSE BRAKE FRICTION CONE
Fig. 81 Reverse Brake Shim
1 ± REVERSE BRAKE SHIM
2 ± REVERSE BRAKE FRICTION CONE
Fig. 82 Gear Case Half
1 ± TRANSAXLE CASE
2 ± BENCH FIXTURE
3 ± GEARTRAIN
21 - 26 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(10) Line up reverse brake friction cone lugs to the
slots in the gear case (Fig. 83). Verify reverse brake
shim is in position.
(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 84).(12) Install shaft snap rings at input and output
bearings (Fig. 85).
(13) Apply MopartRTV sealant to end±cover outer
edge and around bolt holes. Install end±cover onto
gear case. Tighten end cover bolts to 29 N´m (21 ft.
lbs.) torque (Fig. 86).
Fig. 83 Friction Cone Lugs
1 ± CASE
2 ± FRICTION CONE LUGS
3 ± INPUT SHAFT
Fig. 84 Installing Input and Output Bearings
1 ± INPUT AND OUTPUT BEARINGS
2 ± SPECIAL TOOL C-4992-1
Fig. 85 Snap Rings Retaining Bearings
1 ± SNAP RING PLIERS
2 ± SNAP RINGS
Fig. 86 Transaxle End Cover
1 ± TRANSAXLE CASE
2 ± END COVER
PLTRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

(14) Remove gear case from bench fixture.
(15) Install gear case in a holding fixture with end
cover facing down.
(16) Turn selector shaft into slot on blocker assem-
bly (Fig. 87).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers.
(18) Install reverse idler gear and spacer as shown
in (Fig. 88)(19) Install reverse idler shaft (Fig. 89).
(20) Install bolt into shaft and tighten to 26 N´m
(19 ft. lbs.) torque (Fig. 90).
Fig. 87 Selector Shaft
1 ± SHIFT ASSEMBLY
2 ± SELECTOR SHAFT
Fig. 88 Reverse Idler Gear and Spacer
1 ± SPACER
2 ± REVERSE IDLER GEAR
Fig. 89 Reverse Idler Shaft
1 ± REVERSE IDLER SHAFT
Fig. 90 Reverse Idler Shaft Bolt
1 ± CASE
2 ± REVERSE IDLER SHAFT
3 ± REVERSE IDLER SHAFT BOLT
21 - 28 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(21) Install reverse fork bracket and reverse lock-
out. Tighten screws to 11 N´m (96 in. lbs.) torque
(Fig. 91) (Fig. 92).(22) Install differential into gear case (Fig. 93).
BEARING ADJUSTMENT PROCEDURE
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat gives 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
the 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.
Fig. 91 Reverse Fork Bracket
1 ± REVERSE FORK BRACKET
2 ± REVERSE CAM BLOCKOUT
3 ± SHIFT BLOCKER ASSEMBLY
Fig. 92 Reverse Fork Screws
1 ± SCREWS (2)
2 ± REVERSE FORK BRACKET
Fig. 93 Differential Assembly
1 ± INPUT SHAFT
2 ± OUTPUT SHAFT
3 ± DIFFERENTIAL
4 ± CASE
PLTRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

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. 94). 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 in
Step 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. 95).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.
Once proper turning torque has been established,
place gear case on the end plate. Draw a bead of
MopartGasket Maker, Loctitet518, or equivalent,
on the flat surface of the case mating flange. Install
clutch bellhousing onto gear case. Install and tighten
case bolts to 29 N´m (21 ft. lbs.).
Fig. 94 Checking Differential Bearing End Play To
Determine Shim Thickness
1 ± T-HANDLE
2 ± DIAL INDICATOR SET
3 ± SPECIAL TOOL C-4995
Fig. 95 Checking Differential Bearing Turning
Torque
1 ± INCH-POUND TORQUE WRENCH
2 ± SPECIAL TOOL C-4995
21 - 30 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

INPUT SHAFT
DISASSEMBLY
Before disassembly of the input shaft, it is neces-
sary to check the synchronizer stop ring gap. Use a
feeler gauge to measure the gaps between the stop
rings and the speed gears. The correct gaps are listed
below:
²1stÐ1.04-1.72 mm (0.041-0.069 in).
²2ndÐ0.94-1.72 mm (0.038-0.069 in).
²3rdÐ1.37-1.93 mm (0.054-0.076 in).
²4thÐ1.41-1.97 mm (0.056-0.078 in).
²5thÐ1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
cations, it must be inspected for wear and replaced.
If the 1st or 2nd synchronizer stop ring is worn
beyond specifications, the complete output shaft
assembly must be replaced.
The input shaft incorporates the 3rd, 4th, and 5th
speed gears and synchronizers on the assembly (Fig.
96).(1) Install bearing splitter behind 5th speed gear.
Remove snap ring at 5th synchronizer hub on input
shaft (Fig. 97).
(2) Remove synchronizer and gear using shop
press (Fig. 98).
Fig. 96 Input Shaft
1 ± INPUT SHAFT
2 ± STOP RING
3 ± SLEEVE
4 ± 5TH SPEED GEAR
5 ± STOP RING
6 ± SLEEVE
7 ± 4TH SPEED GEAR
8 ± STOP RING
9 ± 3RD SPEED GEAR
Fig. 97 5th Synchro and Hub Snap Ring Removal
1 ± SNAP RING PLIERS
2 ± INPUT SHAFT
3 ± BEARING SPLITTER
4 ± SNAP RING
Fig. 98 Remove Synchronizer Using Shop Press
1 ± PRESS RAM
2 ± INPUT SHAFT
3 ± BEARING SPLITTER
4 ± SYNCHRONIZER ASSEMBLY
PLTRANSAXLE 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)