2000 DODGE NEON Service Repair Manual

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Transfer shaft
²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
STIRRUP AND STRAP INSTALLATION
Once bearing shim selection has been adjusted,
install stirrup and strap assembly onto transfer gear.
NOTE: Once the stirrup assembly is positioned
onto the transfer gear, it is necessary to ªclockº the
stirrup against the flats of the transfer gear retain-
ing nut.
(1) Position the stirrup on the transfer gear.
(2) Position strap.
(3) Install retaining bolts into transfer gear. Fin-
ger±tighten bolts.
(4) Turn stirrup clockwise against the flats of the
transfer gear retaining nut.
(5) Tighten retaining bolts to 23 N´m (200 in. lbs.).(6) Bend tabs of strap up against ªflatsºof retain-
ing bolts.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
Fig. 155 Install Transfer Shaft Bearing Cup
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4520
4 ± TRANSFER SHAFT BEARING RETAINER
5 ± ªOº RING
Fig. 156 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 ± TRANSFER SHAFT GEAR
2 ± TORQUE WRENCH
3 ± SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 157 Checking Transfer Shaft End Play
1 ± SPECIAL TOOL L-4432 AND C-4658
2 ± TRANSFER SHAFT GEAR
3 ± STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 ± DIAL INDICATOR
5 ± SCREW (2)
21 - 120 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

PARKING PAWL
DISASSEMBLY
ASSEMBLY
To install, reverse the above procedure.
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
STIRRUP AND RETAINING STRAP
NOTE: A stirrup and retaining strap (Fig. 161) is
attached to the output gear. The stirrup prevents
the output gear retaining nut from turning and
backing off the output shaft. The strap is used to
hold the stirrup to the output gear and prevent the
stirrup retaining bolts from backing out.
REMOVAL
Fig. 158 Parking Sprag Rod Support
1 ± PARKING SPRAG ROD SUPPORT
2 ± BOLT (2)
3 ± OUTPUT SHAFT GEAR
Fig. 159 Support and Bolts
1 ± BOLT (2)
2 ± PARKING SPRAG ROD SUPPORT
Fig. 160 Parking Pawl, Return Spring, and Pivot
Shaft
1 ± PARKING PAWL
2 ± RETURN SPRING
3 ± NOTE: SMALL DIAMETER TO REAR
4 ± PIVOT SHAFT
Fig. 161 Stirrup and Retaining Strap Assembly
1 ± STRAP
2 ± RETAINING BOLTS (2)
3 ± OUTPUT GEAR
4 ± STIRRUP
PLTRANSAXLE 21 - 121
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Using a punch, bend tabs on strap flat against
output gear (Fig. 162).
(2) Remove bolts holding retaining strap to stirrup
(Fig. 163).(3) Remove strap from output gear and stirrup
(Fig. 164).
(4) Remove stirrup from output gear (Fig. 165)
(Fig. 166).
Fig. 162 Bend Strap Tabs Flat
1 ± RETAINING TABS
2 ± STRAP
Fig. 163 Remove Strap Bolts
1 ± RETAINING BOLTS
2 ± STIRRUP
3 ± STRAP
Fig. 164 Remove Strap From Stirrup and Gear
1 ± OUTPUT GEAR
2 ± STRAP
Fig. 165 Remove Stirrup From Gear
1 ± OUTPUT GEAR
2 ± STIRRUP
21 - 122 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT GEAR AND SHAFT
DISASSEMBLY
Fig. 166 Stirrup and Strap Removed From Output
Gear
1 ± OUTPUT GEAR RETAINING NUT
2 ± OUTPUT GEAR
Fig. 167 Remove Output Shaft Retaining Nut and
Washer
1 ± SPECIAL TOOL L-4434
2 ± OUTPUT SHAFT GEAR
Fig. 168 Remove Output Shaft Gear using L-4407A
1 ± OUTPUT GEAR
2 ± TOOL L-4407A
Fig. 169 Output Shaft Gear and (Select) Shim
1 ± BEARING CUP
2 ± SHIM (SELECT)
3 ± BEARING CONE
4 ± OUTPUT SHAFT GEAR
5 ± OUTPUT SHAFT
PLTRANSAXLE 21 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 170 Remove Output Shaft Gear Bearing Cone
1 ± SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 ± OUTPUT SHAFT GEAR
Fig. 171 Remove Output Shaft and Rear Annulus
Gear Assembly
1 ± BEARING CUP
2 ± REAR ANNULUS GEAR
3 ± OUTPUT SHAFT
Fig. 172 Remove Output Shaft
1 ± ARBOR PRESS RAM
2 ± CAUTION: SUPPORT ANNULUS GEAR UNDERNEATH,
NEAR GEAR CENTER.
3 ± BEARING CONE
4 ± REAR ANNULUS GEAR
5 ± OUTPUT SHAFT
Fig. 173 Remove Rear Planetary Annulus Gear
Bearing Cone
1 ± SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 ± REAR PLANETARY ANNULUS GEAR
21 - 124 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
Fig. 174 Remove Output Shaft Gear Bearing Cup
1 ± OUTPUT SHAFT GEAR BEARING CUP
2 ± SPECIAL TOOL L-4518
Fig. 175 Remove Rear Planetary Annulus Gear
Bearing Cup
1 ± REAR PLANETARY ANNULUS GEAR BEARING CUP
2 ± SPECIAL TOOL L-4518
Fig. 176 Install Output Shaft Gear Bearing Cone
1 ± PRESS
2 ± HANDLE C-4171
3 ± SPECIAL TOOL L-4408
4 ± OUTPUT SHAFT GEAR
5 ± BEARING CONE
Fig. 177 Install Rear Planetary Annulus Gear
Bearing Cone
1 ± ARBOR PRESS RAM
2 ± SPECIAL TOOL C-4637
3 ± REAR PLANETARY ANNULUS GEAR
4 ± CUP FROM TOOL L-4518
5 ± BEARING CONE
PLTRANSAXLE 21 - 125
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearing turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 178 Install Output Shaft into Rear Planetary
Annulus Gear
1 ± PRESS
2 ± 1/2 INCH SOCKET
3 ± OUTPUT SHAFT
4 ± REAR ANNULUS GEAR
5 ± SPACER
Fig. 179 Install Output Shaft Gear Bearing Cup
1 ± OUTPUT SHAFT GEAR BEARING CUP
2 ± SPECIAL TOOL L-4429-3
Fig. 180 Install Rear Planetary Annulus Gear
Bearing Cup
1 ± SPECIAL TOOL L-4429-3
Fig. 181 Install Output Shaft Assembly
1 ± OUTPUT SHAFT ASSEMBLY
2 ± USE GREASE TO HOLD SHIMS IN POSITION
3 ± BEARING CONE
4 ± LUBRICATION HOLE
5 ± SELECT SHIMS
21 - 126 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 182 Output Shaft and (Select) Shims in Position
1 ± BEARING CUP
2 ± (SELECT) SHIM
3 ± OUTPUT SHAFT ASSEMBLY
Fig. 183 Start Output Shaft Gear onto Output Shaft
1 ± OUTPUT SHAFT GEAR
2 ± OUTPUT SHAFT
3 ± SPECIAL TOOL L-4439
Fig. 184 Holding Output Shaft Gear
1 ± OUTPUT SHAFT
2 ± SCREW (2)
3 ± SPECIAL TOOL L-4434 AND C-4658
4 ± WASHER
5 ± NUT
Fig. 185 Tighten Output Shaft Retaining Nut to 271
N´m (200 ft. lbs.)
1 ± OUTPUT SHAFT GEAR
2 ± SPECIAL TOOL L-4434 AND C-4658
3 ± SCREW (2)
Fig. 186 Checking Output Shaft End Play
1 ± SPECIAL TOOL L-4432 AND C-4658
2 ± SCREW (2)
3 ± OUTPUT SHAFT GEAR
4 ± STEEL BALL (GREASE IN PLACE)
5 ± SPECIAL TOOL L-4438
6 ± DIAL INDICATOR
PLTRANSAXLE 21 - 127
DISASSEMBLY AND ASSEMBLY (Continued)