Home ReviewsRefund
Home/Dodge/Neon/Dodge Neon II (1999-2005)/Repair manual/Automatic Trans/Automatic Transmissions: Removal & Installation
Contents Wiring diagrams Section: Automatic Trans All sections

Automatic Transmissions: Removal & Installation Dodge Neon II

Automatic Trans 32 illustrations ~1398 words

REMOVAL

  1. Disconnect battery cables.
  2. Remove hold down and battery.
  3. Remove battery tray.
  4. Remove air cleaner/throttle body assembly.
  5. Using a suitable blade or cutter, cut transaxle oil cooler hoses off flush with end of fittings. A service splice kit will be installed upon reinstallation.
  6. Disconnect input speed sensor connector.
  7. Disconnect output speed sensor connector.
  8. Disconnect solenoid/pressure switch assembly connector.
  9. Disconnect gearshift cable from manual valve.
  10. Disconnect gearshift cable from upper mount bracket. Secure cable out of the way.
  11. Remove starter motor upper mounting bolt.
  12. Raise vehicle on hoist.
  13. Remove halfshafts.
  14. Remove structural collar.
  15. Remove left lateral bending brace.
  16. Remove starter motor and position out of way.
  17. Remove power steering cooler-to-crossmember fasteners. Secure cooler out of way.
  18. Remove right lateral bending brace-to-transaxle bolt.
  19. Remove converter dust shield.
  20. Remove torque converter-to-drive plate bolts.
  21. Remove both lower transaxle bellhousing-to-engine bolts.
  22. Support engine with a screw jack and wood block.
  23. Remove transaxle upper mount through-bolt. Lower engine/transaxle assembly with screw jack.
  24. Obtain helper and transmission jack.
  25. Position transmission jack to transaxle. Secure transaxle to jack.
  26. Remove two (2) transaxle bellhousing-to-block bolts (upper).
  27. Remove transaxle from vehicle.

INSTALLATION

  1. Install transaxle assembly to engine. Install and torque transaxle-to-engine bolts to 108 N.m (80 ft. lbs.).
  2. Raise engine/transaxle assembly into position with screw jack and wood block.
  3. Install and torque transaxle upper mount-to-rail through-bolt to 118 N.m (87 ft. lbs.).
  4. Remove transmission jack and screw jack supports.
  5. Install torque converter-to-drive plate bolts and torque to 88 N.m (65 ft. lbs.).
  6. Install converter dust shield.
  7. Install and torque right lateral bending brace-to-transaxle bolt to 81 N.m (60 ft. lbs.).
  8. Install starter motor assembly.
  9. Install left lateral bending brace. Torque brace-to-transaxle case bolts to 108 N.m (80 ft. lbs.). Torque brace-to-engine bed plate bolt to 54 N.m (40 ft. lbs.). Torque brace-to-intake manifold bolt to 28 N.m (200 in. lbs.).
  10. Install structural collar.
  11. Install power steering oil cooler.
  12. Install halfshafts.
  13. Lower vehicle.
  14. Install gearshift cable to mount. Secure cable end to manual valve lever.
  15. Install solenoid/pressure switch assembly connector.
  16. Connect input speed sensor connector.
  17. Connect output speed sensor connector.
  18. Install cooler lines with service splice kit. Refer to instructions provided with kit.
  19. Install air cleaner/throttle body assembly.
  20. Install battery tray.
  21. Install battery and hold down.
  22. Connect battery cables.
  23. Fill transaxle with suitable amount of fluid. (Refer to «STANDARD PROCEDURE»(ref-178094-S07770570752005061000000) ).

Scheme 157

Scheme 157: 41TE TRANSAXLE HYDRAULIC SCHEMATICS
Scheme 157: 41TE TRANSAXLE HYDRAULIC SCHEMATICS

Scheme 158

Scheme 158
Scheme 158

Scheme 159

Scheme 159
Scheme 159

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161

Scheme 162

Scheme 162
Scheme 162

Scheme 163

Scheme 163
Scheme 163

Scheme 164

Scheme 164
Scheme 164

Scheme 165

Scheme 165
Scheme 165

Scheme 166

Scheme 166
Scheme 166

Scheme 167

Scheme 167
Scheme 167

Scheme 168

Scheme 168
Scheme 168
CAUTIONWhen installing interlock cable assembly, care must be taken not to bend exposed cable wire and slug at shifter end of cable.

Scheme 169

Scheme 169
Scheme 169
  1. Route interlock cable through hole in instrument panel below steering column and around to gear shifter assembly.
  2. Turn the ignition key to the "OFF" or "ON/RUN" position. see scheme 353
  3. Install the interlock cable into the interlock housing at the steering column see scheme 354 Verify the cable snaps into the housing and is fully seated.
  4. Return the ignition key to the "LOCK" position. see scheme 353
  5. Connect the BTSI solenoid connector. see scheme 352
  6. Install cable into retaining clips as shown in see scheme 352
  7. Install steering column upper and lower shrouds. see scheme 351
  8. Install steering column lower cover. see scheme 350
  9. Verify that shifter is in gated "PARK".
  10. Install the cable core end to the plastic cam of the shifter mechanism. Snap the shifter/ignition interlock cable end fitting into the groove in the gear shift mechanism as shown in see scheme 349
  11. Adjust interlock cable/system as follows: If interlock cable is being replaced, it will come with an adjustment pin. Remove the pin from the cable and allow the cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing. If interlock cable is being reused, no pin will be provided. Pry up on cable adjuster lock to release and allow cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing.
  12. Connect battery negative cable and verify interlock system operation as shown in (Scheme 169)
  13. Install shifter bezel. see scheme 348
  14. Install center console assembly. see scheme 347
  15. Install gearshift knob and tighten set screw to 2 N.m (15 in. lbs.). see scheme 346

Scheme 170

Scheme 170: REMOVAL
Scheme 170: REMOVAL

Scheme 171

Scheme 171
Scheme 171

Scheme 172

Scheme 172
Scheme 172

Scheme 173

Scheme 173
Scheme 173

Scheme 174

Scheme 174
Scheme 174
  1. Remove the steering column lower cover. (Scheme 170)
  2. Remove the steering column upper and lower shrouds. (Scheme 171)
  3. Turn the ignition key to the "OFF" or "ON/RUN" position. (Scheme 172)
  4. Grasp the interlock cable and connector firmly. Remove the interlock cable. (Scheme 173)
  5. Remove the two interlock mechanism-to-steering column attaching screws. (Scheme 174) Remove the interlock housing.
  1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 N.m (21 in. lbs.).
  2. Snap the interlock cable into the housing.
  3. Install steering column upper and lower shrouds. (Scheme 171)
  4. Install steering column lower cover. (Scheme 170)

Note. If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. Refer to DIAGNOSIS - 41TE article.

Scheme 175

Scheme 175: REMOVAL
Scheme 175: REMOVAL

Scheme 176

Scheme 176
Scheme 176
  1. Disconnect battery negative cable.
  2. Remove air cleaner/throttle body assembly.
  3. Disconnect solenoid/pressure switch assembly connector.
  4. Disconnect input speed sensor connector.
  5. Remove input speed sensor. (Scheme 175)
  6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts. (Scheme 176)
  7. Remove solenoid/pressure switch assembly and gasket. (Scheme 177) Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports.

Note. If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. Refer to DIAGNOSIS - 41TE article.

Scheme 177

Scheme 177: INSTALLATION
Scheme 177: INSTALLATION
  1. Install solenoid/pressure switch assembly and new gasket to transaxle. (Scheme 177)
  2. Install and torque three (3) bolts (Scheme 176) to 13 N.m (110 in. lbs.).
  3. Install input speed sensor (Scheme 175) and torque to 27 N.m (20 ft. lbs.).
  4. Connect input speed sensor connector.
  5. Install solenoid/pressure switch 8-way connector and torque to 4 N.m (35 in. lbs.).
  6. Install air cleaner/throttle body assembly.
  7. Connect battery negative cable.
  8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Refer to «DIAGNOSIS - 41TE»(ref-137422) article.
  1. Verify O-ring is installed into position.
  2. Install and tighten input speed sensor to 27 N.m (20 ft. lbs.).
  3. Connect speed sensor connector.
  4. Install air cleaner/throttle body assembly.
  5. Connect battery negative cable.
  1. Verify "O" ring is installed into position. see scheme 380
  2. Install and tighten input speed sensor to 27 N.m (20 ft. lbs.).
  3. Connect speed sensor connector.
  4. Connect battery negative cable.
  1. Install transmission range sensor (TRS) to the valve body and torque retaining screw see scheme 385 to 5 N.m (45 in. lbs.).
  2. Install valve body to transaxle. (Refer to «INSTALLATION»(ref-178094-S29448276602005061000000) ).

Note. If valve body is replaced or reconditioned, the TCM Quick Learn Procedure must be performed. Refer to DIAGNOSIS - 41TE article.

Scheme 178

Scheme 178: REMOVAL
Scheme 178: REMOVAL

Scheme 179

Scheme 179
Scheme 179

Scheme 180

Scheme 180
Scheme 180

Scheme 181

Scheme 181
Scheme 181

Scheme 182

Scheme 182
Scheme 182

Scheme 183

Scheme 183
Scheme 183
  1. Disconnect battery negative cable.
  2. Remove air cleaner/throttle body assembly.
  3. Disconnect gearshift cable from manual valve lever.
  4. Remove manual valve lever from manual shaft.
  5. Disconnect transmission range sensor (TRS).
  6. Raise vehicle on hoist.
  7. Remove oil pan bolts. (Scheme 178)
  8. Remove oil pan. (Scheme 179)
  9. Remove oil filter. (Scheme 180)
  10. Remove the valve body-to-transaxle case bolts. (Scheme 181) NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise to low or first gear.
  11. Remove park rod rollers from guide bracket and remove valve body from transaxle. ( (Scheme 182) and (Scheme 183) ). CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped.

Note. If valve body assembly is being replaced or reconditioned, it is necessary to perform the TCM Quick Learn Procedure. Refer to DIAGNOSIS - 41TE article.

Scheme 184

Scheme 184: INSTALLATION
Scheme 184: INSTALLATION

Scheme 185

Scheme 185
Scheme 185

Scheme 186

Scheme 186
Scheme 186

Scheme 187

Scheme 187
Scheme 187

Scheme 188

Scheme 188
Scheme 188
  1. Install valve body assembly to transaxle. (Scheme 185) Install and torque valve body-to-transaxle case bolts to 12 N.m (105 in. lbs.). (Scheme 186)
  2. Install transaxle oil filter. (Scheme 187) Inspect the O-ring and replace if necessary.
  3. Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry. Install an 1/8" bead of Mopar® ATF RTV (MS-GF41) to the oil pan and install. (Scheme 188) Torque oil pan-to-transaxle case bolts to 19 N.m (165 in. lbs.). see scheme 428
  4. Lower vehicle.
  5. Connect transmission range sensor connector.
  6. Install manual valve lever to manual shaft.
  7. Install gearshift cable to manual valve lever.
  8. Install air cleaner/throttle body assembly.
  9. Connect battery negative cable.
  10. Fill transaxle with Mopar® ATF +4 Transmission fluid. (Refer to «FLUID»(ref-178094-S24838499332005061000000) ).

More articles — Automatic Transmissions