2000 DODGE NEON Service Repair Manual

(3) Remove caged needle bearing (Fig. 99).
(4) Remove 4-5 gears split thrust washer ring (Fig.
100).(5) Remove split thrust washer (Fig. 101).
(6) Remove split thrust washer separation pin
(Fig. 102).
Fig. 99 Caged Needle Bearing Removal
1 ± INPUT SHAFT
2 ± CAGED NEEDLE BEARING
Fig. 100 Split Thrust Washer Ring Removal
1 ± SPLIT THRUST WASHER RING
2 ± INPUT SHAFT
Fig. 101 Split Thrust Washer Removal
1 ± INPUT SHAFT
2 ± SPLIT THRUST WASHER
Fig. 102 Split Thrust Washer Separation Pin
1 ± SEPARATION PIN
2 ± INPUT SHAFT
3 ± PLIERS
21 - 32 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Remove 4th gear (Fig. 103).
(8) Remove 4th gear caged needle bearing (Fig.
104). Check the caged needle bearing for a broken
retention spring.(9) Remove blocking ring. Remove 3-4 synchronizer
hub retaining snap ring (Fig. 105).
(10) Install input shaft in shop press. Using bear-
ing splitter, remove 3-4 synchronizer and 3rd gear
(Fig. 106).
(11) Remove 3rd gear caged needle bearing (Fig.
107). Check the caged needle bearing for a broken
retention spring.
(12) Inspect the input shaft for worn or damaged
bearing races or chipped gear teeth. Replace as nec-
essary.
Fig. 103 4th Gear Removal
1 ± INPUT SHAFT
2 ± 4TH GEAR
Fig. 104 Caged Needle Bearing Removal
1 ± INPUT SHAFT
2 ± CAGED NEEDLE BEARING
Fig. 105 3-4 Synchronizer Hub Snap Ring
1 ± SNAP RING PLIERS
2 ± SYNCHRO SNAP RING
3 ± SYNCHRONIZER ASSEMBLY
Fig. 106 3rd Gear Removal
1 ± PRESS RAM
2 ± INPUT SHAFT
3 ± 3RD GEAR
4 ± SYNCHRONIZER ASSEMBLY
PLTRANSAXLE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
The snap rings that are used on the input shaft
are available in select fit sizes. Use the thickest snap
ring that fits in each snap ring groove.
(1) Place input shaft into shop press.
(2) Install 3rd gear caged needle bearing on input
shaft.
(3) Install 3rd gear and 3-4 synchronizer onto
input shaft. Install Tool #C-3717 over input shaft and
press on synchronizer hub and 3rd gear (Fig. 108).
The synchronizer hub has the letterUstamped on
the top face of the hub. This designates that the hub
must be installed with theUfacing upward.(4) Install 3-4 synchronizer snap ring into slot on
input shaft.
(5) Install blocking ring into 3-4 synchronizer.
Install 4th gear caged needle bearing.
(6) Install 4th gear onto input shaft.
(7) Install 4-5 split thrust washer separation pin
(Fig. 109).
(8) Install split thrust washer onto input shaft
(Fig. 110).
Fig. 107 3rd Gear Caged Needle Bearing
1 ± INPUT SHAFT
2 ± 3RD GEAR CAGED NEEDLE BEARING
Fig. 108 Press On 3rd Gear Synchronizer Hub
1 ± PRESS RAM
2 ± SPECIAL TOOL C-3717
3 ± BEARING SPLITTER
4 ± 3RD GEAR SYNCHRONIZER ASSEMBLY
Fig. 109 Split Thrust Washer Separation Pin
Installation
1 ± SEPARATION PIN
2 ± INPUT SHAFT
3 ± PLIERS
Fig. 110 Split Thrust Washer Installation
1 ± INPUT SHAFT
2 ± SPLIT THRUST WASHER
21 - 34 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(9) Install split thrust washer retaining ring (Fig.
111).
(10) Install 5th gear caged needle bearing (Fig.
112).
(11) Using special tool #C-3717, install 5th speed
gear and synchronizer (Fig. 113). The 5th gear syn-
chronizer hub has the letterSstamped on the top
face of the hub. This designates that the hub must be
installed with theSfacing upward.
(12) Install 5th gear synchronizer snap ring (Fig.
114).
Fig. 111 Retaining Ring Installation
1 ± SPLIT THRUST WASHER RING
2 ± INPUT SHAFT
Fig. 112 Caged Needle Bearing Installation
1 ± INPUT SHAFT
2 ± CAGED NEEDLE BEARING
Fig. 113 5th Speed Gear Installation
1 ± PRESS RAM
2 ± SPECIAL TOOL C-3717
3 ± SYNCHRONIZER ASSEMBLY
4 ± BEARING SPLITTER
5 ± 5TH SPEED GEAR
Fig. 114 5th Gear Synchronizer Snap Ring
Installation
1 ± SNAP RING PLIERS
2 ± INPUT SHAFT
3 ± BEARING SPLITTER
4 ± SNAP RING
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT
CAUTION: The output shaft 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 output shaft
assembly.
It is necessary 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 output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 115).
DIFFERENTIAL
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle gear case
²Clutch bellhousing case
²Differential case
²Differential bearings
Refer toBearing Adjustment Procedurein the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
Fig. 115 Output Shaft
1 ± 1ST GEAR
2 ± SLEEVE
3 ± STOP RING
4 ± OUTPUT SHAFT
5 ± 2ND SPEED GEAR
6 ± REVERSE GEAR
7 ± STOP RING
Fig. 116 Remove Differential Bearing Cone
1 ± SPECIAL TOOL C-293-PA
2 ± SPECIAL TOOL C-4996
3 ± DIFFERENTIAL ASSEMBLY
4 ± SPECIAL TOOL C-293-45
21 - 36 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N´m (60 ft. lbs.) torque.
Fig. 117 Install Differential Bearing Cone
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL L-4410
3 ± BEARING CONE
4 ± SPEED SENSOR DRIVE GEAR
Fig. 118 Remove Differential Bearing Cone
1 ± SPECIAL TOOL C-293
2 ± SPECIAL TOOL ADAPTER C-293-45 (USE 4 PIECES)
3 ± DIFFERENTIAL ASSEMBLY
4 ± DIFFERENTIAL BEARING CONE
5 ± SPECIAL TOOL C-4996 (NOTE POSITION)
Fig. 119 Install Differential Bearing Cone
1 ± ARBOR PRESS RAM
2 ± BEARING CONE
3 ± SPECIAL TOOL HANDLE C-4171
4 ± SPECIAL TOOL L-4410
5 ± DIFFERENTIAL ASSEMBLY
Fig. 120 Remove or Install Ring Gear Bolts and
Ring Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± BEARING
3 ± RING GEAR
4 ± RING GEAR BOLTS
PLTRANSAXLE 21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)

SPEEDOMETER DRIVE GEAR
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
REMOVAL
(1) Pry the plastic speedometer drive gear off of
the differential case using a flat blade pry tool (Fig.
121) (Fig. 122).INSTALLATION
NOTE: A new speedometer drive gear must be
installed on differential assembly. The lip on the
speedometer drive gear must be positioned down-
ward when installing onto differential assembly.
(1) Position speedometer drive gear onto differen-
tial assembly (Fig. 123).
(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
124) (Fig. 125). Do not use a hammer.
Fig. 121 Pry Off Speedometer Drive Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 122 Speedometer Drive Gear Removed
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 123 Speedometer Drive Gear
1 ± SPEEDOMETER DRIVE GEAR
2 ± DIFFERENTIAL ASSEMBLY
Fig. 124 Press Gear onto Diferential
1 ± STEEL STOCK
2 ± PRESS RAM
3 ± SPECIAL TOOL L-4440
4 ± DIFFERENTIAL ASSEMBLY
5 ± SPEEDOMETER DRIVE GEAR
21 - 38 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL GEARS
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears. Refer to Speedometer
Drive Gear for service information.
REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 126)
(Fig. 127).(2) Remove pinion shaft (Fig. 128).
Fig. 125 Drive Gear Pressed onto Differential
1 ± PRESS RAM
2 ± SPEEDOMETER DRIVE GEAR
3 ± DIFFERENTIAL ASSEMBLY
Fig. 126 Remove Pinion Shaft Retaining Pin
1 ± RING GEAR
2 ± PINION SHAFT RETAINING PIN
3 ± SPEEDOMETER DRIVE GEAR
Fig. 127 Retaining Pin Removed
1 ± DIFFERENTIAL ASSEMBLY
2 ± SPEEDOMETER DRIVE GEAR
3 ± PINION SHAFT RETAINING PIN
Fig. 128 Pinion Shaft Removal
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± PINION SHAFT RETAINING PIN
PLTRANSAXLE 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)