2000 DODGE NEON differential

(4) Outer C/V joint assembly must be installed on
interconnecting shaft until cross of outer C/V joint
assembly is seated against circlip on interconnecting
shaft (Fig. 41).
(5) Distribute 1/2 the amount of grease provided in
seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into outer C/V joint
assembly housing. Put the remaining amount into
the sealing boot.(6) Install outer C/V joint sealing boot to intercon-
necting shaft clamp evenly on sealing boot.
(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow-
ing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 42). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com-
pletely together, face to face (Fig. 43).
Fig. 39 Sealing Boot Installation on Interconnecting
Shaft
1 ± SEALING BOOT
2 ± RAISED BEAD IN THIS AREA OF SEALING BOOT
3 ± GROOVE
4 ± INTERCONNECTING SHAFT
Fig. 40 Outer C/V Joint Installation on
Interconnecting Shaft
1 ± SOFT FACED HAMMER
2 ± STUB AXLE
3 ± OUTER C/V JOINT
4 ± NUT
Fig. 41 Outer C/V Joint Correctly Installed on
Interconnecting Shaft
1 ± INTERCONNECTING SHAFT
2 ± CROSS
3 ± OUTER C/V JOINT ASSEMBLY
Fig. 42 Crimping Tool Installed on Sealing Boot
Clamp
1 ± SPECIAL TOOL C-4975A
2 ± INTERCONNECTING SHAFT
3 ± CLAMP
4 ± SEALING BOOT
PLDIFFERENTIAL AND DRIVELINE 3 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Seal must not be dimpled, stretched, or
out±of±shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Position outer C/V joint sealing boot into its
retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp evenly
on sealing boot.
(9) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975-A and the fol-
lowing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 44). Tighten nut on crimping
tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 45).
(10) Install the driveshaft requiring boot replace-
ment back on the vehicle. See Driveshaft Removal
and Installation in this section for the required drive-
shaft installation procedure.
Fig. 43 Sealing Boot Retaining Clamp Installed
1 ± CLAMP
2 ± JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 ± INTERCONNECTING SHAFT
4 ± SEALING BOOTFig. 44 Crimping Tool Installed on Sealing Boot
Clamp
1 ± CLAMP
2 ± TRIPOD JOINT HOUSING
3 ± SPECIAL TOOL C-4975A
4 ± SEALING BOOT
Fig. 45 Sealing Boot Retaining Clamp Installed
1 ± CLAMP
2 ± TRIPOD HOUSING
3 ± SPECIAL TOOL C-4975A
4 ± JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 ± SEALING BOOT
3 - 16 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Driveshaft-to-Hub/Bearing
Nut................... 244N´m(180 ft. lbs.)
Knuckle-to-Ball Joint
Bolt/Nut................. 95N´m(70ft.lbs.)
Wheel/Tire-to-Hub/Bearing
Lug Nuts............... 128N´m(95ft.lbs.)
SPECIAL TOOLS
DRIVESHAFT
Boot Clamp Installer C-4975A
Puller 6790
PLDIFFERENTIAL AND DRIVELINE 3 - 17

junction block. A label on the underside of the PDC
cover identifies the locations of the ABS fuses.
(2) Inspect the 25-way electrical connector at the
CAB for damaged, spread, or backed-out wiring ter-
minals. Verify that the 25-way connector is fully
inserted in the socket of the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Look for poor mating of connector halves or ter-
minals not fully seated in the connector body.
(5)
Check for improperly formed or damaged termi-
nals. All connector terminals in a suspect circuit should
be carefully reformed to increase contact tension.
(6) Look for poor terminal-to-wire connections.
This requires removing the terminal from the connec-
tor body to inspect it.
(7) Verify pin presence in the connector assembly
(8) Check for proper ground connections. Check all
ground connections for signs of corrosion, loose fas-
teners, or other potential defects. Refer to the wiring
diagrams for ground locations.
(9) Look for problems with the main power sources
of the vehicle. Inspect the battery, generator, ignition
circuits and other related relays and fuses.
If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record any trouble codes.
Most failures of the ABS disable the ABS function
for the entire ignition cycle even if the fault clears
before key-off. There are some failure conditions,
however, that allow ABS operation to resume during
the ignition cycle in which the trouble occurred even
if the trouble conditions are no longer present.
The following trouble conditions may result in
intermittent illumination of the amber ABS warning
lamp.
²Low system voltage. If Low System Voltage is
detected by the CAB, the CAB will turn on the ABS
Warning Lamp until normal system voltage is
achieved. Once normal voltage is seen at the CAB,
normal operation resumes.
²High system voltage. If high system voltage is
detected by the CAB, the CAB will turn on the
Amber ABS Warning Lamp until normal system volt-
age is achieved. Once normal voltage is again
detected by the CAB, normal ABS operation resumes.
Additional possible causes that may result in the
illumination of the amber ABS warning lamp are as
follows:
²Any condition that interrupts electrical current
to the CAB may cause the amber ABS warning lamp
to turn on intermittently.
²If PCI communication between the body control-
ler and the CAB is interrupted, the body controller
can turn on the amber ABS warning lamp.
TONE WHEEL
Tone wheels can cause erratic wheel speed sensor
signals. Inspect tone wheels for the following possible
causes:
²missing, chipped, or broken teeth
²contact with the wheel speed sensor
²wheel speed sensor to tone wheel alignment
²wheel speed sensor to tone wheel clearance
²excessive tone wheel runout
²tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement,
the drive shaft must be replaced. No attempt should
be made to replace just the tone wheel. Refer to the
DIFFERENTIAL AND DRIVELINE group in this
service manual for removal and installation.
If a rear tone wheel is found to need replacement,
the rear hub and bearing must be replaced. No
attempt should be made to replace just the tone
wheel. Refer to the SUSPENSION group in this ser-
vice manual for removal and installation.
If wheel speed sensor to tone wheel contact is evi-
dent, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and
the tone wheel to ensure it is within specifications.
Refer to SPECIFICATIONS in this section of the ser-
vice manual for the minimum and maximum wheel
speed sensor to tone wheel clearance.
Excessive wheel speed sensor runout can cause
erratic wheel speed sensor signals. Refer to SPECI-
FICATIONS in this section of the service manual for
the maximum allowed tone wheel runout. If tone
wheel runout is excessive, determine if it is caused
by a defect in the driveshaft assembly or hub and
bearing. Replace as necessary.
Tone wheels are pressed onto their mounting sur-
faces and should not rotate independently from the
mounting surface. Replacement of the front drive-
shaft or rear hub and bearing is necessary.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If the fluid sep-
arates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If the brake fluid is contaminated, drain and thor-
oughly flush the brake system. Replace all the rubber
parts or components containing rubber coming into
contact with the brake fluid including: the master
cylinder; proportioning valves; caliper seals; wheel
cylinder seals; ABS hydraulic control unit; and all
hydraulic fluid hoses.
5 - 76 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

(d) Remove mounting bolt and nut (Fig. 10) and
partially remove air cleaner assembly.
(e) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(4) Remove battery tray from bracket.
(5) Disconnect ground cable at battery tray
bracket.
(6) Disconnect back-up lamp switch connector.
(7) Remove bellhousing cap (Fig. 11).
(8) Disconnect clutch cable from release lever and
remove from transaxle (Fig. 11).
(9) Remove shift cable-to-bracket clips (Fig. 12).
(10) Disconnect shift selector and crossover cable
from levers (Fig. 12). Remove cables and secure out
of the way.
(11) Disconnect the vehicle speed sensor connector
(Fig. 13).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 14).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 14).
(17) Remove bellhousing dust cover (Fig. 14).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 15).(19) Remove starter motor (Fig. 16).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 17).
(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
Fig. 10 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCTFWD
Fig. 11 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
Fig. 12 Shift Cables at Transaxle
1 ± SHIFT CABLES
2 ± CLIPS
3 ± BRACKET
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

(8) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(9) Install bellhousing dust cover (Fig. 14).
(10) Install left engine-to-transaxle bending brace
(Fig. 14).(11) Install structural collar (Fig. 14) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(12) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 15).
(13) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(14) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(15) Lower vehicle.
(16) Connect vehicle speed sensor connector (Fig.
13).
(17) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 12).
(18) Connect clutch cable to fork and secure to
transaxle (Fig. 11).
(19) Install bellhousing cap (Fig. 11).
(20) Connect back-up lamp switch connector.
(21) Connect ground strap to transaxle upper
mount bracket.
(22) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
(23) Install the air cleaner/throttle body assy. 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.
(24) Connect the battery cables.
(25) Road test vehicle and inspect for leaks.
Fig. 16 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 17 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
PLCLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)

CAUTION: After removing the steering knuckle from
the ball joint stud, do not pull outward on the knuckle.
Pulling the steering knuckle outward at this point can
separate the inner C/V joint on the driveshaft. Refer to
FRONT DRIVESHAFTS in the DIFFERENTIAL AND
DRIVELINE group for further information.
NOTE: Use caution when separating the ball joint
stud from the steering knuckle, so the ball joint seal
does not get cut.
(6) Separate each ball joint stud from the steering
knuckle by prying down on lower control arm and up
against the ball joint boss on the steering knuckle
(Fig. 3).
(7) If the vehicle is equipped with a power steering
fluid cooler, remove the two screws securing the
cooler to the front suspension crossmember. They are
located behind the cooler and can be accessed from
above. Allow the cooler to hang out of the way.
(8) Using wire or cord, support and tie off the
power steering gear to the underbody of the vehicle,
so when the crossmember is lowered, the gear does
not fall away being held to the vehicle by only the
steering column coupler and the fluid hoses.
(9) Loosen and remove the four bolts attaching the
power steering gear to the front suspension cross-
member (Fig. 4). Remove the power steering gear
from the front suspension crossmember.
(10) Remove the bolt mounting the engine torque
strut to the right forward corner of the front suspen-
sion crossmember (Fig. 5).
NOTE: Before removing the front suspension
crossmember from the vehicle, the location of thecrossmember must be scribed on the body of the
vehicle (Fig. 9). Do this so that the crossmember
can be relocated upon reinstallation against the
body of vehicle in the same location as before
removal. If the front suspension crossmember is
not reinstalled in exactly the same location as
before removal, the preset front wheel alignment
settings (caster and camber) will be lost.
(11) Using an awl, scribe a line (Fig. 6) marking
the location of where the front suspension crossmem-
ber is mounted against the body of the vehicle.
(12) Position a transmission jack under the center
of the front suspension crossmember and raise it to
support the bottom of the crossmember.
(13) Loosen and completely remove the two front
bolts (one right and one left) attaching the front sus-
pension crossmember to the frame rails of vehicle.
The right side bolt can be viewed in the mounting
bolt figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle.
(14) Loosen the two rear bolts (one right and one
left) attaching the front suspension crossmember and
lower control arms to the body of the vehicle until
they release from the threaded tapping plates in the
body of the vehicle. Remove the rear bolts from the
body of the vehicle, but do not completely remove the
rear bolts because they are designed to disengage
from the body threads yet stay within the lower con-
trol arm rear isolator bushing. This allows the lower
control arm to stay in place on the crossmember. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle.
(15) Lower the front suspension crossmember.
Fig. 2 Ball Joint Bolt And Nut
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
Fig. 3 Pry Bar Usage
1 ± STEERING KNUCKLE
2±PRYBAR
3 ± LOWER CONTROL ARM
4 ± BALL JOINT STUD
13 - 6 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

TRANSAXLE
TABLE OF CONTENTS
page page
NV T350 (A-578) MANUAL TRANSAXLE........ 131TH AUTOMATIC TRANSAXLE.............. 54
NV T350 (A-578) MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
GENERAL INFORMATION
NV T350 (A578) MANUAL TRANSAXLE.........1
TRANSAXLE IDENTIFICATION................2
FLUID REQUIREMENTS....................2
SPECIAL ADDITIVES.......................2
SEALANTS..............................2
GEAR RATIOS............................2
GEARSHIFT PATTERN......................3
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES...............3
HARD SHIFTING..........................3
NOISY OPERATION........................3
SLIPS OUT OF GEAR......................3
LOW LUBRICANT LEVEL....................4
FLUID LEAKS............................4
CLUTCH PROBLEMS.......................4
SERVICE PROCEDURES
FLUID DRAIN AND FILL.....................4
REMOVAL AND INSTALLATION
GEARSHIFT KNOB........................4
GEARSHIFT BOOT........................5
GEARSHIFT CABLE ASSEMBLY..............6
GEARSHIFT MECHANISM REPLACEMENT......9
VEHICLE SPEED SENSOR AND DRIVE
PINION...............................11
BACK-UP LAMP SWITCH...................12CROSSOVER LEVER......................12
SELECTOR LEVER.......................12
AXLE SHAFT SEALS......................13
SHIFT SHAFT SEALS......................13
TRANSAXLE............................14
DISASSEMBLY AND ASSEMBLY
TRANSAXLE............................18
INPUT SHAFT...........................31
OUTPUT SHAFT.........................36
DIFFERENTIAL..........................36
SYNCHRONIZER.........................41
SHIFT RAILS OVERHAUL..................42
TRANSAXLE CASE OVERHAUL..............42
CLEANING AND INSPECTION
TRANSAXLE............................48
SYNCHRONIZER.........................48
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE...........49
BEARING ADJUSTMENT PROCEDURE........50
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT..........................50
SPECIFICATIONS
NV T350 (A-578) SPECIFICATIONS...........51
SPECIAL TOOLS
NV T350 (A-578) MANUAL TRANSAXLE........52
GENERAL INFORMATION
NV T350 (A578) MANUAL TRANSAXLE
The NV T350 (A-578) transaxle is a fully synchro-
nized (except reverse), constant-mesh transaxle. The
transaxle case is constructed of die-cast aluminum,
and is a two-piece design (bell housing case half and
rear housing case half) with a steel end plate bearing
cover. All forward gears are in constant-mesh witheach other, which eliminates the need to move gears
together for engagement. This feature improves
response and eliminates gear ªclashº noises. The
reverse idler gear is supported and rotates on a spin-
dle idler shaft. Depending on application, a reverse
gear brake/blocking ring is available on some units
for shifting ease.
The NV T350 (A-578) transaxle also incorporates an
open differential, which converts power from the output
shaft pinion gear to the differential ring gear. The dif-
PLTRANSAXLE 21 - 1