Dodge Neon / Neon SRT-4. Manual — part 337

VEHICLE SPEED SENSOR

REMOVAL

(1) Raise vehicle on hoist.
(2) Remove passenger side halfshaft and interme-

diate shaft assembly. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/HALF SHAFT - REMOVAL)

(3) Disconnect the speed sensor connector (Fig.

213).

CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.

(4) Remove speed sensor retaining bolt (Fig. 213).

(5) Remove speed sensor from transaxle.

CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.

(6) Remove speed sensor drive gear from speed

sensor.

INSTALLATION

(1) Install pinion gear to speed sensor (Fig. 213).
(2) Using a NEW o-ring, install the speed sensor

to the transaxle (Fig. 213).

(3) Install the bolt and torque to 7 N·m (60 in.

lbs.).

(4) Connect speed sensor connector (Fig. 213).
(5) Install intermediate shaft and passenger side

halfshaft. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/HALF SHAFT - INSTALLATION)

(6) Lower vehicle and road test to verify proper

speedometer operation.

Fig. 213 Speed Sensor and Pinion Removal/

Installation—Typical

1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - GEAR

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T850 MANUAL TRANSAXLE

PL/SRT-4

40TE AUTOMATIC TRANSAXLE

TABLE OF CONTENTS

page

page

40TE AUTOMATIC TRANSAXLE

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 134

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 136

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - 4XTE

TRANSAXLE GENERAL DIAGNOSIS . . . . . . 136

DIAGNOSIS AND TESTING - ROAD TEST

. . 137

DIAGNOSIS AND TESTING - HYDRAULIC

PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 137

DIAGNOSIS AND TESTING - CLUTCH AIR

PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 139

DIAGNOSIS AND TESTING - TORQUE

CONVERTER HOUSING FLUID LEAKAGE . . 140

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 141

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 159

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 181

SCHEMATICS AND DIAGRAMS

4XTE TRANSAXLE HYDRAULIC

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 181

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . 194

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . 196

ACCUMULATOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 201

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 202

DRIVING CLUTCHES

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 202

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 202

FINAL DRIVE

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 203

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 203

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 203

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 208

ADJUSTMENTS

DIFFERENTIAL BEARING PRELOAD

MEASUREMENT AND ADJUSTMENT . . . . . . 212

FLUID

STANDARD PROCEDURE

FLUID LEVEL AND CONDITION CHECK

. . . 214

STANDARD PROCEDURE - FLUID AND

FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . 216

RS/CS TRANSMISSION FLUID LEVEL

CHECK PROCEDURE . . . . . . . . . . . . . . . . . 217

GEARSHIFT CABLE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 220

ADJUSTMENTS

GEARSHIFT CABLE

. . . . . . . . . . . . . . . . . . 221

HOLDING CLUTCHES

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 222

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 222

INPUT CLUTCH ASSEMBLY

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 223

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 232

OIL PUMP

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 246

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 247

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 247

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 248

PLANETARY GEARTRAIN

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 249

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 249

SEALS - OIL PUMP

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 250

SHIFT INTERLOCK CABLE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 252

SHIFT INTERLOCK CABLE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 254

SHIFT INTERLOCK SYSTEM

DIAGNOSIS AND TESTING - BRAKE

TRANSMISSION SHIFT INTERLOCK

. . . . . . 254

ADJUSTMENTS

BRAKE TRANSMISSION SHIFT INTERLOCK

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

SOLENOID/PRESSURE SWITCH ASSY

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 256

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 256

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 258

SPEED SENSOR - INPUT

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 258

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 259

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 259

SPEED SENSOR - OUTPUT

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 259

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 260

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 261

TORQUE CONVERTER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 262

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 265

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 267

PL/SRT-4

40TE AUTOMATIC TRANSAXLE

21 - 133

TRANSMISSION CONTROL RELAY

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 267

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 268

TRANSMISSION RANGE SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 268

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 268

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 269

VALVE BODY

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 269

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 270

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 272

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 277

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 281

40TE AUTOMATIC
TRANSAXLE

DESCRIPTION

The 40TE (Fig. 1) is a four-speed transaxle that is

a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:

• Three multiple disc input clutches

• Two multiple disc holding clutches

• Four hydraulic accumulators

• Two planetary gear sets

• Hydraulic oil pump

• Valve body

• Solenoid/Pressure switch assembly

• Integral differential assembly

Control of the transaxle is accomplished by fully

adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).

The PCM/TCM is the heart of the electronic control

system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).

The PCM/TCM also performs certain self-diagnos-

tic functions and provides comprehensive information
(sensor data, DTC’s, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.

21 - 134

40TE AUTOMATIC TRANSAXLE

PL/SRT-4

Fig. 1 40TE Automatic Transaxle

1 - TRANSAXLE CASE

7 - REVERSE CLUTCH

13 - OUTPUT SHAFT GEAR

2 - TORQUE CONVERTER

8 - FRONT PLANET CARRIER

14 - TRANSFER SHAFT GEAR

3 - OIL PUMP

9 - 2/4 CLUTCH

15 - TRANSFER SHAFT

4 - INPUT SPEED SENSOR

10 - L/R CLUTCH

16 - DIFFERENTIAL

5 - UNDERDRIVE CLUTCH

11 - OUTPUT SPEED SENSOR

17 - CONVERTER DRIVE PLATE

6 - OVERDRIVE CLUTCH

12 - REAR PLANET CARRIER/OUTPUT
SHAFT

18 - INPUT SHAFT

PL/SRT-4

40TE AUTOMATIC TRANSAXLE

21 - 135

40TE AUTOMATIC TRANSAXLE (Continued)