Dodge Neon / Neon SRT-4. Manual — part 325
(9) Connect clutch hydraulic plumbing to slave cyl-
inder quick-connect. An audible “click” should be
heard. Verify connection by pulling outward.
(10) Install
halfshafts
and
intermediate
shaft
assembly (Fig. 89). (Refer to 3 - DIFFERENTIAL &
DRIVELINE/HALF SHAFT - REMOVAL)
Fig. 89 Halfshaft and Intermediate Shaft—2.4L Turbo Models
1 - HALFSHAFT - LEFT
2 - HALFSHAFT - RIGHT
3 - SUPPORT BRACKET - INTERMEDIATE SHAFT
4 - INTERMEDIATE SHAFT/BEARING ASSEMBLY
Fig. 87 Lateral Bending Brace
1 - LATERAL BENDING BRACE
2 - BOLT (1 LONG/1 SHORT)
3 - BOLT (2)
Fig. 88 Charge Air Cooler Hose/Fasteners
1 - CAC HOSE ASSY
2 - NUT (2)
21 - 84
T850 MANUAL TRANSAXLE
PL/SRT-4
T850 MANUAL TRANSAXLE (Continued)
(11) Install and torque ABS wheel speed sensors to
12 N·m (105 in. lbs.).
(12) Check and adjust transaxle fluid level if nec-
essary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/FLUID - STANDARD PROCEDURE)
(13) Lower vehicle.
(14) Install gearshift cables to transaxle bracket
and secure with NEW retaining clips.
(15) Install battery tray (Fig. 90).
(16) Install battery (with thermal wrap) and hold
down clamp/bolt. Connect battery temperature sen-
sor.
(17) Install throttle body adapter housing.
(18) Connect accelerator cable while installing
throttle body into position. Install two (2) throttle
body-to-manifold bolts to 28 N·m (250 in. lbs.).
(19) Connect IAC & TPS sensor connectors.
(20) Install intercooler-to-throttle body hose. Con-
nect IAT sensor and TIP hose.
(21) Install air cleaner assembly and connect AAT
sensor.
(22) Install turbo solenoid pack (Fig. 91).
(23) Connect air cleaner inlet tube from turbo-
charger.
SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Transaxle Type
Constant-mesh, fully synchronized 5-speed with integral
differential
Lubrication Method
Splash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type
ATF+4 (Automatic Transmission Fluid—Type 9602) and
4 oz. Mopar
T
Limited Slip Additive
Fig. 90 Battery Tray Removal/Installation
1 - BATTERY TRAY
2 - LEFT STRUT TOWER
3 - PDC
4 - MOUNTING HOLES/SLOTS
5 - COOLANT RESERVOIR
Fig. 91 Turbocharger Solenoids and Mounting
Bracket
1 - TIP SOLENOID
2 - SURGE VALVE ACTUATOR SOLENOID
3 - WASTEGATE ACTUATOR SOLENOID
4 - BRACKET MOUNTING SCREWS
PL/SRT-4
T850 MANUAL TRANSAXLE
21 - 85
T850 MANUAL TRANSAXLE (Continued)
GEAR RATIOS
GEAR
RATIO
1st
3.65
2nd
2.05
3rd
1.37
4th
0.97
5th
0.76
Reverse
3.47
Final Drive Ratio
3.53
INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear
0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear
0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear
0.099-0.505 mm (0.004-0.020 in.)
4th Gear
0.048-0.457 mm (0.002-0.018 in.)
INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear
0.66-1.84 mm (0.026-0.072 in.)
2nd Gear
0.66-1.84 mm (0.026-0.072 in.)
5th Gear
0.86-1.54 mm (0.034-0.061 in.)
Reverse
0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear
0.091-0.828 mm (0.004-0.033 in.)
2nd Gear
0.051-0.787 mm (0.002-0.031 in.)
5th Gear
0.102-0.762 mm (0.004-0.030 in.)
Reverse
0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION
METRIC
STANDARD
Differential Turning Torque
2.3-3.4 N·m
20-30 in. lbs.
Side Gear End Play (each side)
0.025-0.152 mm
0.001-0.006 in.
21 - 86
T850 MANUAL TRANSAXLE
PL/SRT-4
T850 MANUAL TRANSAXLE (Continued)
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Bolt, Bearing Plate-to-Case
28
—
250
Bolt, Differential Cover-to-Case
54
40
—
Bolt, End Cover-to-Case
28
—
250
Bolt, End Cover Plate-to-Cover
28
—
250
Bolt, Reverse Idler Shaft-to-Case
54
40
—
Bolt, Ring Gear-to-Differential Case
95
70
—
Bolt, Shift Cover-to-Case
28
—
250
Nut, 5th Gear-to-Input Shaft
262
193
—
Nut, Impact Blocker
28
21
—
Plug, Drain
23
17
—
Screw, Input Bearing Retainer
12
—
105
Switch, Back-Up Lamp
23
17
—
Vent
7
—
60
SPECIAL TOOLS - T850 TRANSAXLE
Bearing Splitter, P-334
Slide Hammer, C-3752
Universal Handle, C-4171
Torque Tool, C-4995
PL/SRT-4
T850 MANUAL TRANSAXLE
21 - 87
T850 MANUAL TRANSAXLE (Continued)
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