2000 DODGE NEON torque

NOTE: Compressed air supply must be free of all
dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. Refer to Valve
Body for removal procedure.
FRONT CLUTCH
Apply air pressure to front clutch apply passage
and listen for a dull thud, which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
REAR CLUTCH
Apply air pressure to rear clutch apply passage
and listen for a dull thud, which indicates that rear
clutch is operating. Also, inspect for excessive oil
leaks. If a dull thud cannot be heard in the clutches,
place finger tips on clutch housing and again apply
air pressure. Movement of piston can be felt as the
clutch is applied.
KICKDOWN SERVO (FRONT)
Direct air pressure into KICKDOWN SERVO ON
passage. Operation of servo is indicated by a tighten-
ing of front band. Spring tension on servo piston
should release the band.
Fig. 7 Air Pressure Tests
1 ± PUMP SUCTION
2 ± PUMP PRESSURE
3 ± FRONT CLUTCH APPLY
4 ± REAR CLUTCH APPLY
5 ± TO TORQUE CONVERTER
6 ± FROM TORQUE CONVERTER
7 ± TO OIL COOLER
8 ± KICKDOWN SERVO OFF9 ± KICKDOWN SERVO ON
10 ± ACCUMULATOR OFF
11 ± ACCUMULATOR ON
12 ± LOW-REVERSE SERVO APPLY
13 ± GOVERNOR PRESSURE
14 ± LINE PRESSURE TO GOVERNOR
15 ± GOVERNOR PRESSURE PLUG
16 ± GOVERNOR PRESSURE
PLTRANSAXLE 21 - 69
DIAGNOSIS AND TESTING (Continued)

LOW AND REVERSE SERVO (REAR)
Direct air pressure into LOW/REVERSE SERVO
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
ton should release the band.
If clutches and servos operate properly, no upshift
indicates that a malfunction exists in the valve body.
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA
(1) Check for source of leakage.
(2) Since fluid leakage near the torque converter
area may be from an engine oil leak, the area should
be checked closely. Factory fill fluid is dyed red and,
therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
vent in the dipstick. If the fluid level is high, adjust
to proper level.
(6) After performing this operation, inspect for
leakage. If a leak persists, perform the following
operation on the vehicle. This will determine if the
torque converter or transaxle is leaking.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter (peripheral) weld
²Torque converter hub weld
²Torque converter impeller shell cracked adjacent
to hub
²At drive lug welds
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
BRAKE TRANSMISSION SHIFT INTERLOCK
The following chart describes the normal operation
of the Brake Transmission Shift Interlock (BTSI) sys-
tem. If the ªexpected responseº differs from the vehi-
cle's response, then system repair and/or adjustment
is necessary. Refer to Brake Transmission Interlock
Removal and Installation or Adjustment in this
Group.
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE
NOTE: Refer to Group 0, Lubrication and Mainte-
nance, or the vehicle owner's manual, for the rec-
ommended maintenance (fluid/filter change)
intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparT
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist (See Lubrication,
Group 0). Place a drain container with a large open-
ing, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body and tighten retaining screws to 5 N´m (40
in. lbs.).
ACTION EXPECTED RESPONSE
1. Turn key to the ªOFFº
position.1. Shifter CAN be shifted
out of park.
2. Turn key to the
9ON/RUNº position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
ªON/RUNº position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the ªLOCKº or9ACCº
position.4. Key cannot be
returned to the ªLOCKº or
ªACCº position.
5. Return shifter to
ªPARKº and try to remove
the key.5. Key can be removed
(after returning to ªLOCKº
position).
6. With the key removed,
try to shift out of ªPARKº.6. Shifter cannot be
shifted out of ªPARKº.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
21 - 70 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALTERNATIVE MAINTENANCE METHODS
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION: The use of any fluid exchanger that
introduces additives into the transaxle is not rec-
ommended.
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating tempera-
ture.
(2) Obtain a suitable transaxle fluid exchanger
and verify the tank is clean and dry.
(3) Fill the tank to the recommended fill capacity
with MopartATF+4 Type 9602.
(4) Connect the machine to the vehicle following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with MopartATF+4 Type 9602. Refer
to Fluid Level and Condition Check in this group for
the proper fluid ªtop-offº procedure.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N²m (18 in. lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 8).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils. This repair consists of drilling out the
worn-out or damaged threads. Then tap the hole with
a Heli-Coil tap, and install a Heli-Coil insert into the
hole. This brings the hole back to its original thread
size.
Heli-Coil tools and inserts are readily available
from most automotive parts suppliers.
Fig. 8 Dipstick Markings
1 ± TRANSAXLE DIPSTICK
PLTRANSAXLE 21 - 71
SERVICE PROCEDURES (Continued)

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)

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)

(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)

(9) Verify that shifter is in gated ªPARKº.
(10) Install the cable core end to the plastic cam of
the shifter mechanism. Snap the shifter/ignition
interlock cable end fitting into the groove in the gear-
shift mechanism as shown in (Fig. 32).
(11)Adjust interlock cable/system as follows:
If interlock cable is being replaced, it will come with
an adjustment pin. Remove the pin from the cable
and allow the cable to ªself-adjustº. Lock cable
adjustment by pressing down on the adjuster lock
until bottomed at the cable housing. If interlock cable
is being re-used, no pin will be provided. Pry up on
cable adjuster lock to release and allow cable to ªself-
adjustº. Lock cable adjustment by pressing down on
the adjuster lock until bottomed at the cable housing.
(12)Connect battery negative cable and ver-
ify interlock system operation as follows:
(13) Install shifter bezel (Fig. 31).
(14) Install center console assembly (Fig. 30).
(15) Install gearshift knob and tighten set screw to
2 N´m (15 in. lbs.) torque (Fig. 29).
INTERLOCK MECHANISM
REMOVAL
(1) Remove the steering column lower cover (Fig.
39).
(2) Remove the steering column upper and lower
shrouds (Fig. 40).
(3) Turn the ignition key to the ªOFFº or ªON/
RUNº position (Fig. 41).
(4) Grasp the interlock cable and connector firmly.
Remove the interlock cable (Fig. 42).(5) Remove the two interlock mechanism-to-steer-
ing column attaching screws (Fig. 43). Remove the
interlock housing.INSTALLATION
(1) Position the interlock housing at steering col-
umn. Install the two interlock mechanism-to-steering
column attaching screws. Torque screws to 3 N´m (21
in. lbs.).
(2) Snap the interlock cable into the housing.
ACTION EXPECTED RESPONSE
1. Turn key to the ªOFFº
position.1. Shifter CAN be shifted
out of park.
2. Turn key to the
9ON/RUNº position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
ªON/RUNº position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the ªLOCKº or9ACCº
position.4. Key cannot be
returned to the ªLOCKº or
ªACCº position.
5. Return shifter to
ªPARKº and try to remove
the key.5. Key can be removed
(after returning to ªLOCKº
position).
6. With the key removed,
try to shift out of ªPARKº.6. Shifter cannot be
shifted out of ªPARKº.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
Fig. 39 Steering Column Lower Cover
1 ± LOWER COVER
Fig. 40 Steering Column Shrouds
1 ± UPPER SHROUD
2 ± LOWER SHROUD
21 - 82 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)