2000 DODGE NEON differential

To remove the differential bearing cup from the
extension housing/adapter side, use Special Tool
6062A, Remover. To install the differential bearing
cup on the extension housing/adapter side, use Spe-
cial Tool 6536, Driver and Special Tool C-4171, Han-
dle.
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
Fig. 210 Differential Bearing Retainer
1 ± DIFFERENTIAL BEARING CUP
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 211 Position Bearing Cup Remover Tool in
Retainer
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 212 Remove Bearing Cup
1 ± SPECIAL TOOL 6062A
2 ± DIFFERENTIAL BEARING RETAINER
Fig. 213 Install Bearing Cup
1 ± SPECIAL TOOL C-4171
2 ± SPECIAL TOOL 5052
3 ± DIFFERENTIAL BEARING RETAINER
21 - 134 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT BEARING
With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shim on the planetary rear annulus gear hub using
grease to hold the shim in place. The 13.65 mm shim
has a larger inside diameter and must be installed
over the output shaft first. The 1.34 mm shim pilots
on the output shaft.
Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
To measure bearing end play:
(1) Attach Tool L-4432 to the output shaft gear.
(2) Mount a steel ball with grease into the end of
the output shaft.
(3) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(4) Using a dial indicator mounted to the transaxle
case, measure output shaft end play.
(5) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(6) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
that are necessary for proper bearing lubrica-
tion.
(7) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(8) Use tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use tool
L-4407.
(9) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.
(10) Install the retaining nut and washer, and
torque to 271 N´m (200 ft. lbs.).
(11) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(12) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
DIFFERENTIAL BEARING
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft.
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential.
OUTPUT SHAFT BEARING SHIM CHART
Fig. 222 Tool L-4436 and Torque Wrench
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
3 ± DIFFERENTIAL BEARING RETAINER
PLTRANSAXLE 21 - 139
ADJUSTMENTS (Continued)

The turning torque should be between 5 and 18
inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e)
NOTE: If the turning torque was too high when
measured, install a.05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a.05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differen-
tial.The turning torque should be between 5
and 18 inch-pounds.
TRANSFER SHAFT BEARING
(1) Use tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
a. Attach tool L-4432 to the transfer gear.
b. Mount a steel ball with grease into the end of
the transfer shaft.
c. Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
d. Using a dial indicator, measure transfer shaft
end play.
e. Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
f. Use tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using tool
L-4407.
Fig. 223 Checking Differential Bearings Turning
Torque
1 ± SPECIAL TOOL L-4436±A
2 ± TORQUE WRENCH
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
21 - 140 TRANSAXLEPL
ADJUSTMENTS (Continued)

SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
Type .........Automatic three speed with torque
converter and integral differential
Torque Converter Diameter...... 241millimeters
(9.48 in.)
OilType .....................MopartATF+4
(Automatic Transmission Fluid) Type 9602
Cooling Method.... Water Heat Exchanger and/or
air to oil heat exchanger
Lubrication . . . Pump (internal-external gear-type)
Transmission Gear Ratios
First Gear............................2.69
Second Gear...........................1.55
Third Gear............................1.00
Reverse Gear..........................2.10
Band Adjustment
KickdownÐBacked Off From 8 N²m
(72 in. lbs.).................... 21/4Turns
Low-ReverseÐBacked Off From 5 N²m
(41 in. lbs.).................... 31/2Turns
Clutch Pack Clearances
Front Clutch (Not Adjustable)......1.27-2.79mm
(0.050-0.110 in.)
Rear Clutch.......0.71-1.10mm (0.028-0.043 in.)
End Play
Input Shaft........0.19±1.50 mm (.008±.060 in.)
Front Clutch Retainer...........0.76±2.69 mm
(.030±.106 in.)
Front Carrier.......0.89±1.45 mm (.007±.057 in.)
Front Annulus Gear . . 0.09±0.50 mm (.0035±.020 in.)
Planet Pinion.......0.15±0.59 mm (.006±.023 in.)
Reverse Drum......0.76±3.36 mm (.030±.132 in.)
Oil Pump Clearances
Outer Gear To Pocket...........0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.......0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . 6 to 12 in. lbs. Drag Torque
Output Hub.......... 0to3in.lbs. Drag Torque
Transfer Shaft.......0.002 to 0.010 in. End Play
Overall Drag At Output
Hub ............. 3to16in.lbs. Drag TorqueThrust Washers
Reaction Shaft Support (No. 1).....1.55±1.60 mm
(.061±.063 in.)
Rear Clutch Retainer (No. 2)......1.55±1.60 mm
(.061±.063 in.)
Output Shaft (No. 3) (Select)......1.98±2.03 mm
(.077±.080 in.)
Output Shaft (No. 3) (Select)......2.15±2.22 mm
(.085±.087 in.)
Output Shaft (No. 3) (Select)......2.34±2.41 mm
(.092±.095 in.)
Front Annulus (No. 4)............2.95±3.05 mm
(.116±.120 in.)
Front Carrier (Nos. 5&6).........1.22±1.28 mm
(.0948±.050 in.)
Sun Gear-Front (No. 7)...........0.85±0.91 mm
(.033±.036 in.)
Sun Gear-Rear (No. 8)...........0.85±0.91 mm
(.033±.036 in.)
Rear Carrier (Nos. 9&10).........1.22±1.28 mm
(.0948±.050 in.)
Rev. Drum (No. 11) . . 1.55±1.60 mm (.061±.063 in.)
31TH TRANSAXLE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Bell Housing Cover Bolts.... 12N´m(105 in. lbs.)
Cooler Line Clamps.......... 2N´m(18in.lbs.)
Diff. Bear. Ret. To Case Bolt . . 34 N´m (300 in. lbs.)
Diff. Cover To Case Bolt..... 19N´m(165 in. lbs.)
Exten. Hous. To Case Bolt . . . 28 N´m (250 in. lbs.)
Drive Plate To Crankshaft
Bolts................... 95N´m(70ft.lbs.)
Drive Plate To Torque Conv.
Bolts................... 88N´m(65ft.lbs.)
Fluid Filter Screw........... 5N´m(45in.lbs.)
Governor Counterweight
Screw................. 28N´m(250 in. lbs.)
Governor To Support Bolt...... 7N´m(60in.lbs.)
Kickdown Band Adj. Lock Nut . . 47 N´m (35 ft. lbs.)
Left Motor Mount Bolts....... 54N´m(40ft.lbs.)
Manual Cable To Trans.
Case Bolt.............. 28N´m(250 in. lbs.)
Manual Control Lever Screw . . 12 N´m (105 in. lbs.)
Oil Pan To Trans. Case
Screw................. 19N´m(165 in. lbs.)
Output Gear Strap Bolts...... 23N´m(17ft.lbs.)
Output Shaft Nut......... 271N´m(200 ft. lbs.)
Park/Neutral Switch......... 34N´m(25ft.lbs.)
Pressure Check Plug......... 5N´m(45in.lbs.)
Pump To Case Bolts........ 31N´m(275 in. lbs.)
Reaction Shaft Assembly
Bolt................... 28N´m(250 in. lbs.)
Rear Cover To Case Screw . . . 19 N´m (165 in. lbs.)
Reverse Band Adj. Lock Nut . . 14 N´m (125 in. lbs.)
21 - 150 TRANSAXLEPL

Gear Checking Plate L-4432
Gear Removing Plate L-4434
Bearing Puller L-4435
Differential Tool L-4436A
Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
21 - 154 TRANSAXLEPL
SPECIAL TOOLS (Continued)

TIRE WEAR PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 4).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 4).
TIRE NOISE OR VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, vibration, wheel
defects, or possibly tire imbalance.To find out if tires are causing the noise or vibra-
tion, drive the vehicle over a smooth road at varying
speeds. Note the noise level during acceleration and
deceleration. The engine, differential and exhaust
noises will change as speed varies, while the tire
noise will usually remain constant.
VEHICLE LEAD DIAGNOSIS AND CORRECTION
Use the following chart to diagnose a vehicle that
has a complaint of a drift or lead condition. The use
of this chart will help to determine if the lead condi-
tion is the result of a bad tire or is caused by the
wheel alignment.
Fig. 4 Tire Wear Patterns
22 - 4 TIRES AND WHEELSPL
DIAGNOSIS AND TESTING (Continued)

REMOVAL
(1) Remove the wire connector from the low pres-
sure cut-off switch.
(2) Remove the center bolt of refrigerant line
plumbing sealing plate (Fig. 37).
(3) Carefully pull the refrigerant line-sealing plate
assembly from the expansion valve towards front of
vehicle. Do not scratch the expansion valve sealing
surfaces with pilot tubes.
(4) Cover the openings on A/C line-sealing plate
assembly to prevent contamination.
(5) Remove two screws securing the expansion
valve to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket on
the evaporator sealing plate.
(2) Carefully hold the expansion valve to the evap-
orator sealing plate so not to scratch the sealing sur-
face. Install two screws and tighten to 1163 N´m
(100630 in. lbs.).
(3) Remove and replace the aluminum gasket on
the refrigerant line- sealing plate assembly.
(4) Carefully hold the refrigerant line-sealing plate
assembly to the expansion valve. Install bolt and
tighten to 2363 N´m (200630 in. lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
HEATER CORE
Refer to HVAC Housing Disassembly and Assembly
in this section for heater core removal procedure.
HEATER HOSES
CAUTION: When removing hoses from heater core
inlet or outlet nipples DO NOT exert excess pres-
sure. The heater core may become damaged and
leak engine coolant.
NOTE: Review Cooling System Precautions before
proceeding with this operation.
REMOVAL
(1) Drain engine cooling system. Refer to Group 7,
Cooling System.
(2) Using spring tension clamp pliers, remove
clamps at end of heater hose to be removed (Fig. 38).
(3) Carefully rotate hose back and forth while pull-
ing away from connector nipple.INSTALLATION
For installation, reverse the above procedures.
Fig. 37 Expansion Valve - Typical
1 ± ALUMINUM N-GASKET
2 ± PLUMBING SEALING PLATE
3 ± LOW/DIFFERENTIAL PRESSURE CUT-OFF SWITCH
4 ± DASH PANEL
5 ± H-VALVE
6 ± EVAPORATOR SEALING PLATE
7 ± H-VALVE
Fig. 38 Heater Hoses and Clamps
1 ± COWL PANEL
2 ± HEATER HOSE AND CLAMPS
3 ± HEATER CORE TUBES
4 ± HEATER HOSE SUPPLY AND RETURN TUBES
24 - 28 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)