2000 DODGE NEON oil filter

mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
(6) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 132) is
0.203 mm (0.008 inch) or more, replace both rotors.(7) Place a straightedge across the face of the
pump housing, between bolt holes. If a feeler gauge
of 0.102 mm (0.004 inch) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 133).ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 60.7 mm (2.39 inches) it should test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 inches). Replace spring that fails to meet
specifications.
(10) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings, damaged
or missing oil pick-up tube O-ring, clogged oil pick-up
tube screen, clogged oil filter and stuck open pres-
sure relief valve or other reasons for oil pressure
loss.
CYLINDER BLOCK AND BORE
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Engine
Core Plugs in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
Fig. 131 Measuring Outer Rotor Clearance in
Housing
1 ± FEELER GAUGE
2 ± OUTER ROTOR
Fig. 132 Measuring Clearance Between Rotors
1 ± FEELER GAUGE
2 ± INNER ROTOR
3 ± OUTER ROTOR
Fig. 133 Measuring Clearance Over Rotors
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
PL2.0L SOHC ENGINE 9 - 65
CLEANING AND INSPECTION (Continued)

DESCRIPTION SPECIFICATION
Exhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25 mm
(0.010 in.)
Exhaust 0.0736±0.094 mm
(0.0029±0.0037 in.)
Max. Allowable 0.101 mm
(0.004 in.)
Service Limit 0.25 mm
(0.010 in.)
Valve Springs
Free Length (Approx.) 46.75 mm
(1.84 in.)
Nominal Force (Valve
Closed)331 N @ 39.8 mm
(70 lbs. @ 1.57 in.)
Nominal Force (Valve
Open)711 N @ 32.6 mm
(160 lbs. @ 1.28 in.)
Installed Height 40.18 mm
(1.580 in.)
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Camshaft Sensor
Pick-upÐBolts9.6 Ð 85
Camshaft SprocketÐBolt 115 85 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20 +
1¤4
turnÐ
Structural CollarÐBolts Refer to Procedure
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 34 25 Ð
ÐM11 Bolts 81 60 Ð
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts Refer to Procedure
Cylinder Head CoverÐ
Bolts12 Ð 105
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Drive Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine Mounting Refer to Procedure
Exhaust Manifold to
Cylinder HeadÐBolts23 Ð 200
Exhaust Manifold Support
Bracket (Federal and
LEV)
ÐM8 Nut 28 Ð 250
ÐM10 Bolt 54 40 Ð
ÐM12 Bolt 95 70 Ð
Exhaust Manifold Support
Bracket (ULEV)54 40 Ð
Engine Torque Strut
Bracket to EngineÐBolts61 45 Ð
Powertrain Bending
StrutÐFront
ÐLong Bolts 101 75 Ð
ÐShort Bolts 61 45 Ð
Intake ManifoldÐBolts 12 Ð 105
Oil Filter Adaptor 80 60 Ð
Oil Filter 20 15 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump to Block 28 Ð 250
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Pump Relief
ValveÐCap41 30 Ð
PCV Valve 5.6 Ð 50
Rocker Arm ShaftÐBolts 28 Ð 250
Spark Plugs 28 Ð 250
Timing Belt CoverÐBolts 12 Ð 105
Timing Belt Tensioner
AssemblyÐBolts28 Ð 250
Water PumpÐBolts 12 Ð 105
PL2.0L SOHC ENGINE 9 - 71
SPECIFICATIONS (Continued)

(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 15).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Install fuel tank, refer to the Fuel Tank remov-
al/installation section.
(6) Lower vehicle.
(7) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL FILTER/FUEL
PRESSURE REGULATOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 16) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 17).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 15 Fuel Tank Locknut
1 ± SPECIAL TOOL 6856
2 ± LOCKNUT
Fig. 16 Locking Spring Tab
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
Fig. 17 Spring Tab In Locating Slot
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
PLFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)

31TH AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
GENERAL INFORMATION
IN VEHICLE SERVICE.....................55
FLUID REQUIREMENTS...................55
DESCRIPTION AND OPERATION
31TH GENERAL INFORMATION..............55
FLUID LEVEL AND CONDITION..............56
TORQUE CONVERTER CLUTCH.............56
HYDRAULIC CONTROL SYSTEM.............56
PRESSURE SUPPLY SYSTEM...............56
PRESSURE REGULATING VALVES...........56
FLOW CONTROL VALVES..................56
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR........................57
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM..............................57
GEARSHIFT AND PARKING LOCK CONTROLS . . 57
COOLER BYPASS VALVE..................57
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR...................58
GOVERNOR.............................58
DIAGNOSIS AND TESTING
TRANSAXLE PRELIMINARY DIAGNOSIS.......58
ROAD TEST.............................65
HYDRAULIC PRESSURE TESTS.............66
CLUTCH AND SERVO AIR PRESSURE TESTS . . 68
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA.............70
BRAKE TRANSMISSION SHIFT INTERLOCK....70
SERVICE PROCEDURES
TRANSAXLE FLUID AND FILTER SERVICE.....70
ALUMINUM THREAD REPAIR...............71
FLUSHING COOLERS AND TUBES...........72
OIL PUMP VOLUME CHECK................72
REMOVAL AND INSTALLATION
GEARSHIFT CABLE.......................73
GEARSHIFT MECHANISM..................76
THROTTLE VALVE (KICKDOWN) CABLE.......77
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE...............................79
INTERLOCK MECHANISM..................82
VEHICLE SPEED SENSOR PINION GEAR......83
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH.........................84TRANSAXLE AND TORQUE CONVERTER......84
PUMP OIL SEAL.........................88
DISASSEMBLY AND ASSEMBLY
TRANSAXLE............................89
VALVE BODY............................91
OIL PUMP.............................104
FRONT CLUTCH........................105
REAR CLUTCH ASSEMBLY................108
FRONT PLANETARY AND ANNULUS
GEAR-RECONDITION...................110
LOW/REVERSE (REAR) SERVO-
RECONDITION........................112
ACCUMULATOR-RECONDITION............113
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................113
TRANSFER SHAFT REPAIR................114
PARKING PAWL.........................121
OUTPUT SHAFT REPAIR..................121
DIFFERENTIAL REPAIR...................129
CLEANING AND INSPECTION
VALVE BODY...........................135
ADJUSTMENTS
GEARSHIFT CABLE......................135
THROTTLE VALVE CABLE ADJUSTMENT
PROCEDURE.........................136
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM.............................137
BAND ADJUSTMENT.....................138
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS.......................138
BEARING ADJUSTMENT PROCEDURES......138
OUTPUT SHAFT BEARING................139
DIFFERENTIAL BEARING.................139
TRANSFER SHAFT BEARING..............140
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 142
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE.............150
31TH TRANSAXLE TORQUE SPECIFICATIONS . 150
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE.............151
21 - 54 TRANSAXLEPL

GENERAL INFORMATION
IN VEHICLE SERVICE
The following components are serviceable in the
vehicle without transaxle removal:
²Valve Body Assembly
²Converter Clutch Solenoid
²Governor
²Vehicle Speed Sensor & Pinion
²Park/Neutral & Back-up Lamp Switch
²Transfer Gears and Transfer Shaft
²Low/Reverse Servo
²Kickdown Servo
²Accumulator
FLUID REQUIREMENTS
NOTE: The transmission and differential have a
common oil sump with an opening between the
two.
TRANSMISSION/DIFFERENTIAL
MopartATF+4 (Automatic Transmission Fluid
Type 9602) is required in this transaxle. Substitute
fluids must meet fluid specification MS-9602.
FLUID ADDITIVES
Chrysler Corporation strongly recommends against
the addition of any fluids to the transmission, other
than those automatic transmission fluids listed
above. Exceptions to this policy are the use of special
dyes to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel/quality and converter
clutch operation, inhibit overheating, oxidation, var-
nish and sludge. These claims have not been sup-
ported to Chrysler's satisfaction and these additives
must not be used. The use of transmission ªsealersº
should also be avoided, since they may adversely
affect the integrity of tranmission seals.
DESCRIPTION AND OPERATION
31TH GENERAL INFORMATION
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
fluid through a remote cooler. There are two types of
coolers used. An oil-to-water type cooler located in
the radiator side tank and/or an oil-to-air heat
exchanger. The torque converter assembly is a sealed
unit that cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.
Engine torque is transmitted to the torque con-
verter and then through the input shaft to multiple-
disc clutches in the transaxle. The power flow
depends on the application of the clutches and bands.
Refer to Elements in Use Chart in Diagnosis and
Tests section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The driving shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor in the
transaxle final drive (axle) ratio. The shaft also car-
ries the governor and parking sprag. An integral heli-
cal gear on the transfer shaft drives the differential
ring gear.
PLTRANSAXLE 21 - 55

Hydraulic pressure tests should be performed
when a transaxle internal failure is suspected. The
hydraulic flow charts, in the Schematics and Dia-
grams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
all gear ranges. Normal working pressures are also
supplied for each of the gear ranges.
TRANSAXLE DIAGNOSIS CHARTS
CONDITION POSSIBLE CAUSES CORRECTION
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)1. Fluid Level Low 1. Add Fluid
2. Throttle Linkage Misadjusted 2. Adjust linkage - setting may be too long.
3. Excessive Pinion Backlash 3. Check per Service Manual. Correct as
needed.
4. Hydraulic Pressure Incorrect 4. Check pressure. Remove, overhaul or
adjust valve body as needed.
5. Band Misadjusted. 5. Adjust rear band.
6. Valve Body Check Balls Missing. 6. Inspect valve body for proper check ball
installation.
7. Clutch, band or planetary
component Damaged.7. Remove, disassemble and repair
transmission as necessary.
8. Converter Clutch (if equipped)
Faulty.8. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Rear Band Misadjusted. 4. Adjust band.
5. Valve Body Filter Plugged. 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
6. Oil Pump Gears Worn/Damaged. 6. Remove transmission and replace oil
pump.
7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove
transmission and repair as needed.
8. Reaction Shaft Seal Rings
Worn/Broken.8. Remove transmission, remove oil pump
and replace seal rings.
9. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.9. Remove and disassemble transmission
and repair as necessary.
10. Governor Valve Stuck. 10. Remove and inspect governor
components. Replace worn or damaged
parts.
11. Regulator Valve Stuck. 11. Clean.
PLTRANSAXLE 21 - 59
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE RANGE
(REVERSE OK)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. Filter Plugged. 3. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
4. Oil Pump Damaged. 4. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
5. Valve Body Malfunctioned. 5. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.
6. Transmission Internal Component
Damaged.6. Remove and disassemble transmission.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.
7. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.7. Remove, disassemble, repair.
8. Torque Converter Damage. 8. Inspect and replace as required.
21 - 60 TRANSAXLEPL
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
3. Rear Band Misadjusted. 3. Adjust band.
4. Rear Band Worn. 4. Replace as required.
5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.
6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.
7. Band Linkage Binding. 7. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).8. Replace Clutch.
SLIPS IN LOW GEAR ªDº
ONLY, BUT NOT IN 1
POSITIONOverrunning Clutch Faulty. Replace overrunning clutch.
PLTRANSAXLE 21 - 63
DIAGNOSIS AND TESTING (Continued)