Dodge Neon / Neon SRT-4. Manual — part 346
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 109).
(29) Install bearing cup retainer to transaxle (Fig.
110).
(30) Install transfer gear bearing cone to transfer
gear using Tool 5052 (Fig. 111).
Fig. 108 Install Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 109 Install Transfer Shaft Bearing Cup Into
Retainer
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
Fig. 110 Install Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 111 Install Transfer Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052
21 - 168
40TE AUTOMATIC TRANSAXLE
PL/SRT-4
40TE AUTOMATIC TRANSAXLE (Continued)
(31) TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 112).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N·m (200 ft. lbs.).
(c) Measure end play. Attach Tool L4432 to the
transfer gear.
(d) Mount a steel ball with grease into the end
of the transfer shaft.
(e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers.
(f) Using a dial indicator, measure transfer shaft
end play.
(g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting.
(h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A.
(i) Remove the gauging shim (Fig. 112) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play
Shim Needed
Part Number
End Play
Shim Needed
Part Number
0.05mm
(0.002 in.)
4.66mm
(0.183 in.)
4505588AB
0.76mm
(0.030 in.)
3.94mm
(0.155 in.)
4412818AB
0.08mm
(0.003 in.)
4.62mm
(0.182 in.)
4412835AB
0.79mm
(0.031 in.)
3.90mm
(0.154 in.)
4412817AB
0.10mm
(0.004 in.)
4.58mm
(0.180 in.)
4412834AB
0.81mm
(0.032 in.)
3.90mm
(0.154 in.)
4412817AB
0.13mm
(0.005 in.)
4.58mm
(0.180 in.)
4412834AB
0.84mm
(0.033 in.)
3.86mm
(0.152 in.)
4412816AB
0.15mm
(0.006 in.)
4.54mm
(0.178 in.)
4412833AB
0.86mm
(0.034 in.)
3.82mm
(0.150 in.)
4412815AB
0.18mm
(0.007 in.)
4.50mm
(0.177 in.)
4412832AB
0.89mm
(0.035 in.)
3.82mm
(0.150 in.)
4412815AB
0.20mm
(0.008 in.)
4.50mm
(0.177 in.)
4412832AB
0.91mm
(0.036 in.)
3.78mm
(0.149 in.)
4412814AB
0.23mm
(0.009 in.)
4.46mm
(0.175 in.)
4412831AB
0.94mm
(0.037 in.)
3.74mm
(0.147 in.)
4412813AB
0.25mm
(0.010 in.)
4.46mm
(0.175 in.)
4412831AB
0.97mm
(0.038 in.)
3.74mm
(0.147 in.)
4412813AB
0.28mm
(0.011 in.)
4.42mm
(0.174 in.)
4412830AB
0.99mm
(0.039 in.)
3.70mm
(0.146 in.)
4412812AB
0.30mm
(0.012 in.)
4.38mm
(0.172 in.)
4412829AB
1.02mm
(0.040 in.)
3.66mm
(0.144 in.)
4412811AB
0.33mm
(0.013 in.)
4.38mm
(0.172 in.)
4412829AB
1.04mm
(0.041 in.)
3.66mm
(0.144 in.)
4412811AB
Fig. 112 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
PL/SRT-4
40TE AUTOMATIC TRANSAXLE
21 - 169
40TE AUTOMATIC TRANSAXLE (Continued)
End Play
Shim Needed
Part Number
End Play
Shim Needed
Part Number
0.36mm
(0.014 in.)
4.34mm
(0.171 in.)
4412828AB
1.07mm
(0.042 in.)
3.62mm
(0.143 in.)
4412810AB
0.38mm
(0.015 in.)
4.30mm
(0.169 in.)
4412827AB
1.08mm
(0.043 in.)
3.62mm
(0.143 in.)
4412810AB
0.41mm
(0.016 in.)
4.30mm
(0.169 in.)
4412827AB
1.12mm
(0.044 in.)
3.58mm
(0.141)
4412809AB
0.43mm
(0.017 in.)
4.26mm
(0.168 in.)
4412826AB
1.14mm
(0.045 in.)
3.54mm
(0.139 in.)
4412808AB
0.46mm
(0.018 in.)
4.22mm
(0.166 in.)
4412825AB
1.17mm
(0.046 in.)
3.54mm
(0.139 in.)
4412808AB
0.48mm
(0.019 in.)
4.22mm
(0.166 in.)
4412825AB
1.19mm
(0.047 in.)
3.50mm
(0.138 in.)
4412807AB
0.50mm
(0.020 in.)
4.18mm
(0.165 in.)
4412824AB
1.22mm
(0.048 in.)
3.46mm
(0.136 in.)
4412806AB
0.53mm
(0.021 in.)
4.18mm
(0.165 in.)
4412824AB
1.24mm
(0.049 in.)
3.46mm
(0.136 in.)
4412806AB
0.56mm
(0.022 in.)
4.14mm
(0.163 in.)
4412823AB
1.27mm
(0.050 in.)
3.42mm
(0.135 in.)
4412805AB
0.58mm
(0.023 in.)
4.10mm
(0.161 in.)
4412822AB
1.30mm
(0.051 in.)
3.38mm
(0.133 in.)
4412804AB
0.61mm
(0.024 in.)
4.10mm
(0.161 in.)
4412822AB
1.32mm
(0.052 in.)
3.38mm
(0.133 in.)
4412804AB
0.64mm
(0.025 in.)
4.06mm
(0.160 in.)
4412821AB
1.35mm
(0.053 in.)
3.34mm
(0.132 in.)
4412803AB
0.66mm
(0.026 in.)
4.02mm
(0.158 in.)
4412820AB
1.37mm
(0.054 in.)
3.34mm
(0.132 in.)
4412803AB
0.69mm
(0.027 in.)
4.02mm
(0.158 in.)
4412820AB
1.40mm
(0.055 in.)
3.30mm
(0.130 in.)
4412802AB
0.71mm
(0.028 in.)
3.98mm
(0.157 in.)
4412819AB
1.45mm
(0.057 in
3.26mm
(0.128 in.)
4412801AB
0.74mm
(0.029 in.)
3.94mm
(0.155 in.)
4412818AB
1.47mm
(0.058 in.)
2.22mm
(0.127 in.)
4505570AB
21 - 170
40TE AUTOMATIC TRANSAXLE
PL/SRT-4
40TE AUTOMATIC TRANSAXLE (Continued)
(32) Install the transfer shaft gear using Tool 6261
(Fig. 113).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N·m (200 ft. lbs.) (Fig. 114).
(35) Measure transfer shaft end play. Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.). If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of Mopar
t ATF RTV (MS-GF41)
to transfer gear cover (Fig. 115).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N·m (175 in. lbs.) torque (Fig. 116).
(38) Install low/reverse clutch pack (Fig. 117).
Leave uppermost disc out until snap ring is installed.
Fig. 113 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 114 Tighten Nut to 271 N
•
m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 115 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR
T
ATF RTV (MS-GF41) AS SHOWN
Fig. 116 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
PL/SRT-4
40TE AUTOMATIC TRANSAXLE
21 - 171
40TE AUTOMATIC TRANSAXLE (Continued)
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