Dodge Neon / Neon SRT-4. Manual — part 305
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Vehicle must be level to accurately
check fluid level. Leakage is evident by the pres-
ence of oil around the leak point. If leakage is not
evident, the condition is probably the result of an
underfill.
If air–powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
(1) Raise hood.
(2) Disconnect both battery cables, remove battery
hold down clamp and bolt, and remove battery.
(3) Remove air cleaner/throttle body assy. (Fig.
5)as follows:
(a) Disconnect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(b) Disconnect
the
Throttle
Position
Sensor
(TPS) and Idle Air Control (IAC) connectors.
(c) Disconnect throttle body air duct at intake
manifold.
(d) Remove mounting bolt and nut (Fig. 5) and
partially remove air cleaner assembly.
(e) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(4) Remove battery tray from bracket.
(5) Disconnect
ground
cable
at
battery
tray
bracket.
(6) Disconnect back-up lamp switch connector.
(7) Remove shift cable-to-bracket clips (Fig. 6).
(8) Disconnect shift selector and crossover cable
from levers (Fig. 6). Remove cables and secure out of
the way.
(9) Disconnect the vehicle speed sensor connector
(Fig. 7).
Fig. 5 Air Cleaner Assembly Removal/Installation
1 - AIR CLEANER ASSY.
2 - THROTTLE BODY DUCT
Fig. 6 Shift Cables at Transaxle
1 - SHIFT CABLES
2 - CLIPS
3 - BRACKET
21 - 4
T350 MANUAL TRANSAXLE
PL/SRT-4
T350 MANUAL TRANSAXLE (Continued)
(10) Raise vehicle on hoist.
(11) Disconnect and suspend clutch slave cylinder
from transaxle (Fig. 8) (Fig. 9).
(12) Remove transaxle oil drain plug and drain oil
into a suitable container.
(13) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(14) Remove structural collar (Fig. 10).
(15) Remove the left engine-to-transaxle lateral
bending brace (Fig. 10).
(16) Remove bellhousing dust cover (Fig. 10).
Fig. 7 Vehicle Speed Sensor Connector
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - SPEEDO PINION
Fig. 8 Clutch Slave Cylinder at Transaxle—1.6L
Models
1 - SLAVE CYLINDER
2 - BOLT
Fig. 9 Clutch Slave Cylinder at Transaxle—2.0L
Models
1 - SLAVE CYLINDER
2 - BRACKET
Fig. 10 Left Lateral Bending Brace and Structural
Collar—Typical
1 - SUPPORT BRACKET
2 - STRUCTURAL COLLAR
3 - DUST COVER
PL/SRT-4
T350 MANUAL TRANSAXLE
21 - 5
T350 MANUAL TRANSAXLE (Continued)
(17) Remove the right engine-to-transaxle lateral
bending brace (Fig. 11).
(18) Remove starter motor (Fig. 12).
(19) Remove four (4) modular clutch-to-drive plate
bolts. While removing bolts, one tight-tolerance (slot-
ted) drive plate hole will be encountered. When this
bolt is removed, mark driveplate and modular clutch
assembly at this location, and be sure to align marks
upon reassembly.
(20) Support engine at oil pan with screw jack and
wood block.
(21) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver’s side
wheel house (Fig. 13).
(22) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(23) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 14).
(24) Remove transaxle from vehicle (Fig. 14).
(25) If installing a new or replacement transaxle,
remove the upper mount as shown in (Fig. 15), trans-
fer to the replacement unit and torque all bolts to 68
N·m (50 ft. lbs.) torque.
DISASSEMBLY
The T350 transaxle internal components can be
serviced only by separating the gear case from the
bellhousing case.
CAUTION: The transaxle output shaft is serviced as
a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
(1) Place transaxle on bench.
(2) Remove the clutch release bearing and lever.
Move the release fork and bearing to an in-line posi-
tion. Grasp the release lever with two hands in the
Fig. 11 Right Lateral Bending Brace Removal/
Installation—Typical
1 - TRANSAXLE
2 - ENGINE
3 - LATERAL BENDING BRACE
Fig. 12 Starter Motor Removal/Installation—Typical
1 - BOLT
2 - GROUND
3 - STARTER
4 - BOLT
Fig. 13 Transaxle Upper Mount Thru-Bolt—Typical
1 - MOUNT BRACKET
2 - BOLT
3 - MOUNT
21 - 6
T350 MANUAL TRANSAXLE
PL/SRT-4
T350 MANUAL TRANSAXLE (Continued)
pivot stud socket area. Pull with even pressure to
release the lever from the pivot stud.
CAUTION: Do not use a screwdriver or pry bar to
release the lever as this may cause damage to the
lever and/or clip.
(3) Remove shift levers by driving out the roll pins.
(4) Remove transaxle case half bolts (Fig. 16).
(5) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 17). Separate
the case halves (Fig. 18).
Fig. 14 Transaxle Removal/Installation—2.0L Shown
1 - MODULAR CLUTCH ASSEMBLY
2 - CLIP
3 - TRANSAXLE
4 - CLUTCH MODULE BOLT (4)
Fig. 15 Transaxle Upper Mount and Bracket
1 - MOUNT
2 - TRANSAXLE
Fig. 16 Case Bolts
1 - CASE BOLTS
PL/SRT-4
T350 MANUAL TRANSAXLE
21 - 7
T350 MANUAL TRANSAXLE (Continued)
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