Chrysler Neon 1995-1999 Repair Guide

Automatic Transaxle Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 13

The transaxle and torque converter must be removed as an assembly; otherwise the torque converter drive plate, pump bushing or oil seal may be damaged. The drive plate will not support a load; therefore, none of the weight of the transaxle should be allowed to rest on the plate during removal.

  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance.
  4.  
  5. Remove the battery heat shield, then remove the battery from the engine compartment. Remove the battery tray from the engine compartment. If equipped, disconnect the cruise control.
  6.  
  7. Remove the vehicle speed sensor wiring.
  8.  
  9. Disconnect the neutral safety switch and torque converter control wiring from the transaxle.
  10.  


WARNING
Pry up on both sides of the shift cable isolator bushing, evenly, to avoid damaging the cable isolator bushing.

  1. Disconnect the gear shift cable end from the transaxle shift lever. Remove the bracket bolt from the transaxle.
  2.  



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Fig. Fig. 1: Disconnect the gear shift cable end from the transaxle shift lever ...



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Fig. Fig. 2: ... then remove the bracket bolt from the transaxle

  1. Remove the throttle pressure control cable from the lever. Then, remove the bracket bolts from the transaxle.
  2.  



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Fig. Fig. 3: Location of the throttle pressure control cable bracket

  1. Remove the transaxle dipstick tube.
  2.  
  3. Disconnect the transaxle oil cooler lines, and plug them to prevent contamination from entering.
  4.  



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Fig. Fig. 4: You must plug or cap the transaxle cooler lines after disconnecting them

  1. Remove the throttle pressure control cable support bracket bolts. Remove the upper bellhousing bolts and upper starter bolt.
  2.  



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Fig. Fig. 5: Remove the upper bellhousing and starter bolts

  1. Install a suitable engine bridge fixture, then support the engine.
  2.  



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Fig. Fig. 6: Install a suitable bridge fixture to support the engine

  1. Raise and safely support the vehicle, then remove the front wheel and tire assemblies.
  2.  


WARNING
When installing the halfshafts, new retaining clips must be used. Do NOT reuse the old clips. Failure to use new clips could cause the inner CV-joint to disengage.

  1. Remove both front halfshafts, as outlined earlier in this section.
  2.  


WARNING
On 1998-99 vehicles, then exhaust flex joint must be disconnected from the exhaust manifold anytime the engine is lowered. If the engine is lowered while the flex pipe is attached, damage will occur.

  1. On 1998-99 vehicles, remove the bolts securing the exhaust flex joint to the exhaust manifold. Disconnect the exhaust pipe from the manifold.
  2.  
  3. Unfasten the transaxle-to-rear lateral bending strut from the engine and transaxle.
  4.  



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Fig. Fig. 7: Remove the bending strut from the engine and transaxle

  1. Remove the front engine bracket through-bolt. Remove the front engine bracket bolts.
  2.  



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Fig. Fig. 8: Unfasten the front engine bracket bolts

  1. Remove the lower starter bolt.
  2.  



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Fig. Fig. 9: Location of the lower starter bolt

  1. Remove the lower dust shield screw.
  2.  
  3. Rotate the engine clockwise to get access to the converter bolts. Remove the torque converter bolts, then matchmark the converter to the flex plate for alignment during installation.
  4.  



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Fig. Fig. 10: You must rotate the engine clockwise ...



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Fig. Fig. 11: ... to access and remove the torque converter bolts

  1. Support the transaxle with a transaxle jack.
  2.  
  3. Remove the left mount through-bolt. Remove the left mount bolts from the transaxle, then remove the left mount.
  4.  



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Fig. Fig. 12: Remove the left mount through bolt ...



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Fig. Fig. 13: ... then remove the left mount bolts

  1. Remove the rear engine bolt from the transaxle.
  2.  
  3. Carefully work the transaxle and torque converter assembly rearward off the engine block dowels. Disengage the converter hub from the end of the crankshaft. Attach a small C-clamp to the edge of the bell housing. This will hold the torque converter in place during transaxle removal. Lower the transaxle and remove the assembly from under the vehicle.
  4.  

To install:
  1. Installation is the reverse of the removal procedure. Please note the following important steps.
  2.  
  3. The following items must be tightened to the specifications listed.

    Bell housing cover bolts: 9 ft. lbs. (12 Nm)
     
    Transaxle oil cooler line-to-radiator connection: 9 ft. lbs. (12 Nm).
     
    Transaxle oil cooler line connection: 21 ft. lbs. (28 Nm).
     
    Flex plate-to-crankshaft bolts:70 ft. lbs. (95 Nm).
     
    Flex plate-to-torque converter bolts: 10 ft. lbs. (68 Nm).
     
    Left motor mount bolts: 40 ft. lbs. (14 Nm).
     
    Transaxle-to-cylinder block bolt:70 ft. lbs. (95 Nm).
     

  4.  
  5. If the torque converter was removed from the transaxle, be sure to align the pump inner gear pilot flats with the torque converter impeller hub flats.
  6.  
  7. Adjust the gearshift and throttle cables.
  8.  
  9. Refill the transaxle with the suitable type and amount of automatic transaxle fluid. For more information, please refer to General Information & Maintenance of this guide.
  10.  
  11. Make sure the car's back-up lights and speedometer are working properly.
  12.  

ADJUSTMENTS



Gearshift Cable

See Figure 14

Normal operation of the park/neutral position switch provides a quick check to confirm proper linkage adjustment.

Move the gear selector lever slowly forward until it clicks into the Park position. The starter should operate.

After checking the Park position, move the selector slowly toward the Neutral position, until the lever drops into the N position. If the starter will operate also at this point, the gearshift linkage is properly adjusted. If the starter fails to operated in either position, linkage adjustment is necessary, as follows:

  1. Set the parking brake.
  2.  
  3. Remove the floor console, as outlined in Body & Trim of this guide.
  4.  
  5. Place the gearshift lever in the Park (P) position.
  6.  
  7. Push down on the tab and unsnap the collar at the shifter cable to allow the cable to be adjusted.
  8.  



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Fig. Fig. 14: Gearshift cable adjustment

  1. Move the gear shift lever on the transaxle to the Park (P) position.
  2.  
  3. Make sure the shift lever and transaxle are in Park. Rotate the collar on the shift cable adjuster end up until it seats against the plastic housing.
  4.  
  5. If the collar will not rotate to the fully detented lock position, rotate the collar back to its initial unlocked position. Position the transaxle in the gated Park position. Apply a slight load to the shift lever, fore or aft in the vehicle, while at the same time, rotating the collar up to the LOCK position. The collar must seat against the plastic housing to attain the detented lock position. the gearshift linkage should now be adjusted properly.
  6.  
  7. Check adjustment as follows:
    1. Detent position for Neutral and Drive should be within the limits of the hand lever gate stops.
    2.  
    3. Key start must occur only when the shift lever is in the Park or Neutral position.
    4.  

  8.  

Throttle Pressure Cable

See Figure 15

The throttle pressure cable adjustment is crucial to the proper operation of the transaxle. This adjustment positions a valve which controls shift speed, shift quality and part throttle downshift sensitivity. If the setting is too long, early shifts and slippage between shifts may occur. If the setting is too short, shifts may be delayed and part throttle downshifts may be sensitive.

  1. Perform the transaxle throttle cable pressure adjustment while the engine is at the normal operating temperature.
  2.  
  3. Release the cross-lock on the cable assembly (pull the cross-lock upward).
  4.  



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Fig. Fig. 15: Throttle pressure cable adjuster lock

  1. To ensure proper adjustment, the cable must be free to slide all the way toward the engine, against its stop, after the cross-lock is released.
  2.  
  3. Move the transaxle throttle control lever fully clockwise, against its internal stop, and press the crosslock downward into the locked position.
  4.  

The adjustment is complete and transaxle throttle cable backlash was automatically removed. Test the cable freedom of movement by moving the transaxle throttle lever forward (counterclockwise). Then, slowly release it to confirm the it will return fully rearward (clockwise).

No lubrication is required for any component of the throttle cable system.

 
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