Chrysler Neon 1995-1999 Repair Guide

Manual Transaxle Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 9

  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Position the PDC aside for working clearance.
  4.  
  5. Remove the battery heat shield, then remove the battery from the vehicle. Remove the battery tray from the engine compartment. If equipped, disconnect the cruise control.
  6.  
  7. Remove the vehicle speed sensor wire.
  8.  
  9. Detach the back-up lamp switch wiring from the transaxle.
  10.  


WARNING
Pry with equal amounts of force on both sides of the shifter cable isolator bushing to avoid damaging the cable isolator bushing.

  1. Use 2 prytools to disconnect both gear shift cable ends from the transaxle shift levers.
  2.  



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Fig. Fig. 1: Use 2 prytools to disconnect the gear shift cable ends from the shift levers

  1. Remove the clutch housing vent cap, exposing the clutch cable end and clutch release lever. Then, remove the clutch cable from the transaxle bellhousing.
  2.  



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Fig. Fig. 2: Pull the clutch cable backward, to disconnect the clutch cable from the bellhousing



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Fig. Fig. 3: Remove the clutch cable from the lever

  1. Unfasten the retaining bolts, then remove the shift cable (linkage) mounting bracket.
  2.  



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Fig. Fig. 4: Exploded view of the linkage mounting bracket

  1. If equipped, remove the accelerator cable shield.
  2.  
  3. Remove the intake manifold support bracket and the upper starter bolt.
  4.  
  5. Remove the upper bellhousing bolt.
  6.  
  7. Install a suitable engine bridge fixture and support the engine securely.
  8.  
  9. Raise and safely support the vehicle, then remove the front wheel and tire assemblies.
  10.  
  11. Position a suitable drain pan under the vehicle, then drain the transaxle.
  12.  
  13. Remove both front halfshafts, as outlined later in this section.
  14.  


WARNING
When installing the halfshafts, new driveshaft retaining clips MUST be used. NEVER reuse the old clips. If you do not use new clips, the inner CV-joint may disengage.

  1. Remove the power hop damper and bracket.
  2.  
  3. Remove the lower starter mounting bolt.
  4.  



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Fig. Fig. 5: Remove the lower starter mounting bolts

  1. Remove the transaxle-to-rear lateral bending strut from the engine and transaxle.
  2.  



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Fig. Fig. 6: Unfasten the 2 bolts, then remove the bracket (strut) from the engine and transaxle

  1. Support the transaxle with a suitable jack.
  2.  
  3. Remove the front motor mount through-bolt. Remove the front motor mount bolts from the engine and transaxle.
  4.  
  5. Remove the lower dust shield screw and dust shield.
  6.  
  7. Rotate the crankshaft clockwise in order to access the driveplate-to-modular clutch bolts.
  8.  

For installation purposes, matchmark the driveplate and pressure plate before removing any bolts.

  1. Unfasten the 4 driveplate-to-modular clutch bolts in order to separate the driveplate from the clutch.
  2.  
  3. Push the modular clutch assembly into the transaxle bellhousing for easier transaxle removal.
  4.  
  5. Remove the frame rail-to-left transaxle mount through bolt.
  6.  
  7. Remove the left transaxle mount from the transaxle. Then, push the mount up to get clearance for transaxle removal.
  8.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the left transaxle mount through-bolt

  1. Remove the transaxle from the vehicle.
  2.  
  3. Remove the modular clutch assembly from the transaxle input shaft.
  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.

    Dust shield: 9 ft. lbs. (12 Nm)
     
    Front engine mount-to-transaxle:80 ft. lbs. (108 Nm)
     
    Front mount through bolt: 45 ft. lbs. (61 Nm)
     
    Front mount-to-engine bolt: 40 ft. lbs. (54 Nm)
     
    Lateral bending strut bolts: 40 ft. lbs. (54 Nm)
     
    Left mount through bolt: 80 ft. lbs. (108 Nm)
     
    Left mount-to-transaxle bolt: 40 ft. lbs. (54 Nm)
     
    Power hop damper bolts:40 ft. lbs. (54 Nm)
     
    Transaxle-to-engine bolt: 70 ft. lbs. (95 Nm)
     
    Transaxle-to-engine intake bracket bolts: 70 ft. lbs. (95 Nm)
     

  4.  
  5. After installing the transaxle, before lowering the vehicle to the floor, fill the transaxle to the bottom of the fill plug hole with Mopar® type M.S. 9417 or equivalent manual transaxle fluid.
  6.  
  7. Make sure the vehicle's back-up lights and speedometer are functioning properly.
  8.  
  9. After installing the transaxle in the vehicle, you must adjust the crossover cable in order to ensure proper shifter adjustment. Adjust as follows:
    1. Remove the floor shift console from the vehicle.
    2.  
    3. Loosen the adjusting screw on the crossover cable at the shifter.

      Click image to see an enlarged view

      Fig. Fig. 8: Loosen the adjusting screw on the crossover cable at the shifter

    4.  
    5. Pin the transaxle crossover cable in the 3-4 neutral position using a 1 / 4 in. drill bit. Align the hole in the crossover lever with the hole in the boss on the transaxle case. Make sure the drill bit goes into the transaxle case at least 1 / 2 in.

      Click image to see an enlarged view

      Fig. Fig. 9: Insert a 1/4 drill bit to pin the crossover lever into the 3-4 neutral position

    6.  
    7. The shifter is spring loaded and self centering. Allow the shifter to rest in its neutral position. Tighten the adjustment screw to 70 inch lbs. (8 Nm). You must be careful to avoid moving the shift mechanism off-center during screw tightening.
    8.  
    9. Remove the drill bit from the transaxle case and perform a functional check by shifting the transaxle into all gears.
    10.  
    11. Reinstall the center shift console. Blouse the boot out around the console. Seat the boot lip on the top of the console.
    12.  

  10.  
  11. Road test the vehicle to make sure the transaxle is operating properly.
  12.  

 
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