2000 DODGE NEON Service Repair Manual

FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the transaxle oil cooler(s) must be flushed (both
radiator and remote). The cooler bypass valve in the
transaxle must be replaced also. The torque con-
verter must also be replaced with an exchange unit.
This will ensure that metal particles or sludged oil
are not later transferred back into the reconditioned
(or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIT CIGARETTES, SPARKS, FLAMES, AND
OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readingsand clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
Fluid) Type 9602.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with MopartATF+4
(Automatic Transmission Fluid) Type 9602. The vol-
ume should be checked using the following proce-
dure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using MopartATF+4 (Automatic Trans-
mission Fluid) Type 9602.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
21 - 72 TRANSAXLEPL
SERVICE PROCEDURES (Continued)

REMOVAL AND INSTALLATION
GEARSHIFT CABLE
REMOVAL
(1) Loosen set screw and remove knob from shifter
handle (Fig. 9).
(2) Remove the center console assembly as shown
in (Fig. 10).(3) Remove shifter bezel (Fig. 11).
(4) Disconnect shift cable from shifter assembly as
shown in (Fig. 12).
(5) Remove three grommet plate to floor pan nuts
as shown in (Fig. 12).
Fig. 9 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 10 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 11 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 12 Gearshift Cable at Shifter Assembly
1 ± SHIFTER ASSEMBLY
2 ± GROMMET PLATE NUT
3 ± SHIFT CABLE
PLTRANSAXLE 21 - 73

(6) Disconnect both battery cables, remove battery
hold down clamp and bolt, and remove battery.
(7) Remove air cleaner/throttle body assy. (Fig. 13)
as follows:
(a) Disconnect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(b) Disconnect the Throttle Position Sensor
(TPS) and Idle Air Control (IAC) connectors.
(c) Remove mounting bolt and nut (Fig. 13) and
partially remove air cleaner assembly.
(d) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(8) Remove battery tray from bracket.
(9) Disconnect shifter cable from shift lever and
remove from bracket (Fig. 14).
(10) Raise vehicle on hoist.
(11) Remove catalytic converter heat shield (Fig.
15).
(12) Remove intermediate pipe heat shield front
bolts.
(13) Remove remaining grommet plate screw and
remove cable assembly from vehicle (Fig. 16).
Fig. 13 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
Fig. 14 Gear Shift Cable at Transaxle
1 ± SHIFT LEVER
2 ± SHIFT CABLE
Fig. 15 Catalytic Converter Heat Shield
1 ± CONVERTER HEAT SHIELD
21 - 74 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install cable assembly through floor pan open-
ing and secure to floor pan with grommet plate and
one screw (Fig. 16). Make sure the three grommet
plate studs protrude through cable assembly and
floor pan and tighten screw to 7 N´m (60 in. lbs.).
(2) Route transaxle end of cable assembly into
engine compartment and over transaxle assembly.
(3) Install and tighten intermediate pipe heat
shield front screws.
(4) Install catalytic converter heat shield (Fig. 15).
(5) Install gear shift cable to bracket and connect
to shift lever (Fig. 14).
(6) Install and tighten the three grommet plate-to-
floor pan nuts. Tighten to 6 N´m (50 in. lbs.) torque.
(7) Connect gearshift cable to shifter assembly as
shown in (Fig. 12).
(8) Install shifter bezel (Fig. 11).
(9)Adjust gearshift cable as follows:
(a) Place gearshift lever in the PARK (P) posi-
tion.
(b) Loosen shift cable adjustment screw (Fig.
17).
(c) Verify transaxle is in the PARK (P) position
and the shifter lever is in gated PARK..
(d) Tighten shift cable adjustment screw to 8
N´m (70 in. lbs.) torque.
(10) Install battery tray.
(11) Install battery and hold down clamp.
(12) Install the air cleaner/throttle body assy. (Fig.
13) 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.
(13) Install center console assembly (Fig. 10).
(14) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 9).
(15) Connect battery cables.
(16) Verify that engine starter operates in both
PARK (P) and NEUTRAL (N). Starter should not
operate in any other gear position.
Fig. 16 Grommet Plate/Shift Cable at Floor Pan
1 ± GROMMET PLATE
2 ± SHIFT CABLE
Fig. 17 Gearshift Cable Adjustment Screw
1 ± GEARSHIFT CABLE ADJUSTMENT SCREW
PLTRANSAXLE 21 - 75
REMOVAL AND INSTALLATION (Continued)

GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable and isolate.
(2) Loosen set screw and remove knob from shifter
handle (Fig. 18).
(3) Remove the center console assembly as shown
in (Fig. 19).(4) Remove shifter bezel (Fig. 20).
(5) Disconnect shift cable from shifter assembly as
shown in (Fig. 21).
Fig. 18 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 19 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
Fig. 20 Shifter Bezel Removal/Installation
1 ± BEZEL
2 ± SCREW (4)
Fig. 21 Gearshift Cable at Shifter Assembly
1 ± SHIFTER ASSEMBLY
2 ± GROMMET PLATE NUT
3 ± SHIFT CABLE
21 - 76 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(6) Disconnect the shifter/ignition interlock cable
from the shifter lever and bracket as shown in (Fig.
22).
(7) Remove the four shifter assembly-to-floor pan
nuts and remove shifter assembly from vehicle (Fig.
23).INSTALLATION
(1) Install gearshift mechanism and tighten the
four nuts to 12 N´m (105 in. lbs.) torque.
(2) Install gearshift cable as shown in (Fig. 21).
(3) Install shifter/ignition interlock cable as shown
in (Fig. 22).
(4) Install shifter bezel (Fig. 20).
(5) Install center console assembly (Fig. 19).
(6) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 18).
THROTTLE VALVE (KICKDOWN) CABLE
REMOVAL
(1) Remove air cleaner/throttle body assy. (Fig. 24)
as follows:
(a) Disconnect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(b) Disconnect the Throttle Position Sensor
(TPS) and Idle Air Control (IAC) connectors.
(c) Disconnect throttle body air duct at intake
manifold.
(d) Remove mounting bolt and nut (Fig. 24) and
partially remove air cleaner assembly (leave cables
attached).
NOTE: Pay attention to throttle valve cable routing
before removal so it can be re-installed in the same
manner. For proper transaxle operation, the cable
must not bind.
Fig. 22 Shifter Ignition Interlock Cable
1 ± INTERLOCK CABLE
2 ± SHIFTER ASSEMBLY
Fig. 23 Gearshift Mechanism Removal/Installation
1 ± SHIFTER ASSEMBLY
2 ± NUT (4)Fig. 24 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
PLTRANSAXLE 21 - 77
REMOVAL AND INSTALLATION (Continued)

(2) Disconnect throttle valve cable from air clean-
er/throttle body assembly as shown in (Fig. 25).
(3) Disconnect throttle valve cable from lever on
transaxle and remove from bracket (Fig. 26).INSTALLATION
NOTE: Route throttle valve cable in a manner that
allows free, unobstructed travel. For proper tran-
saxle operation, the cable must not bind.
(1) Install transaxle throttle valve cable to bracket
and lever as shown in (Fig. 26). Make sure the cable
snapsonto the lever.
(2) Install the throttle valve cable to the air clean-
er/throttle body as shown in (Fig. 25).
(3) Install the air cleaner/throttle body assy. as fol-
lows:
(a) 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.
(b) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(c) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(d) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(4) Connect the battery negative cable.
(5) Perform the Throttle Valve Cable Adjustment
Procedure found in this group.
(6) Road test vehicle and verify proper transaxle
operation.
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE
The transmission throttle valve is operated by a
cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine
throttle body lever.
The throttle valve is located within the transaxle
valve body and is responsible for transaxle shift
speed, shift quality, and part-throttle downshift sen-
sitivity. Proper cable adjustment is essential for
proper transaxle operation.
NOTE: The air cleaner/throttle body assembly must
be installed into position before making this adjust-
ment.
Fig. 25 Throttle Valve Cable at Air Cleaner/Throttle
Body
1 ± KICKDOWN CABLE
2 ± AIR CLEANER/THROTTLE BODY ASSY.
Fig. 26 Throttle Valve Cable at Transaxle
1 ± LEVER
2 ± BRACKET
3 ± KICKDOWN CABLE
21 - 78 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(1) Verify cable is routed properly with no kinked
or binding conditions.
(2) Release adjustment locking clip on cable at
throttle body.It is not necessary to remove clip.
(3) Grab cable conduit near adjustment body, push
in towards throttle body, then release grip (Fig. 27).
This allows cable to self adjust.
(4) Press locking clip to secure cable position (Fig.
28).
(5) Road test vehicle to verify proper transaxle
operation.BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Loosen set screw and remove knob from shifter
handle (Fig. 29).
(3) Remove the center console assembly as shown
in (Fig. 30).
Fig. 27 Throttle Valve Cable Adjustment
1 ± TAB UNLOCKED
Fig. 28 Cable Locking Clip
1 ± TAB LOCKED
2 ± THROTTLE VALVE CABLE
Fig. 29 Gearshift Knob Removal/Installation
1 ± SHIFTER KNOB
2 ± SET SCREW
Fig. 30 Center Console Removal/Installation
1 ± CONSOLE
2 ± SCREW (4)
3 ± SCREW (2)
PLTRANSAXLE 21 - 79
REMOVAL AND INSTALLATION (Continued)