DODGE NEON 1999 Service Service Manual

(5) Install the disc brake caliper to steering
knuckle attaching bolts (Fig. 61). Tighten the attach-
ing bolts to a torque of 31 N´m (23 ft. lbs.).
(6) Install front wheel and tire. Install front wheel
lug nuts and torque to 135 N´m
(7) (100 ft. lbs.).
(8) Lower vehicle.
DISASSEMBLY AND ASSEMBLY
McPHERSON STRUT
DISASSEMBLY
(1) Clamp the strut assembly in a vise, with the
strut in a vertical position.When clamping the
strut assembly in the vise, do not clamp strut
using the body of the strut only by strut clevis
bracket (Fig. 67).
(2) Mark coil spring and strut assembly right or
left, according to which side of the vehicle the strut
was removed from, and which strut coil spring was
removed from.
WARNING: DO NOT REMOVE STRUT ROD NUT,
BEFORE STRUT ASSEMBLY COIL SPRING IS COM-
PRESSED, REMOVING SPRING TENSION FROM
UPPER SPRING SEAT AND BEARING ASSEMBLY.
WARNING: WHEN COMPRESSING COIL SPRING
FOR REMOVAL FROM STRUT ASSEMBLY, THE
FIRST FULL TOP AND BOTTOM COIL OF THE COILSPRING MUST BE CAPTURED BY THE JAWS OF
THE COIL SPRING COMPRESSOR (Fig. 68).
(3) Compress the strut assembly coil spring, using
Spring Compressor, Special Tool C-4838 (Fig. 68).
(4) Install Socket, Strut Nut, Special Tool L-4558A
(or L-4558) on the strut shaft retaining nut (Fig. 69).
Then install a 10 mm socket on the hex of the strut
damper shaft (Fig. 69). While holding strut shaft
from turning, remove the strut shaft retaining nut.
(5) Remove the strut assembly mount/isolator (Fig.
70) from the strut.
(6) Remove the upper spring seat, pivot bearing
and dust shield as an assembly (Fig. 71) from the
strut.
Fig. 67 Strut Assembly Correctly Clamped In Vise
Fig. 68 Compressing Strut Assembly Coil Spring
Fig. 69 Strut Shaft Retaining Nut Removal Tools
2 - 30 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(7) Remove the jounce bumper (Fig. 72) from the
shaft of the strut assembly.(8) Remove the coil spring from the strut assembly
(Fig. 73).Mark left and right on the coil springs
for their installation back on the correct side of
the vehicle.
WARNING: IF A REPLACEMENT COIL SPRING IS
TO BE INSTALLED ON THE STRUT ASSEMBLY, THE
FIRST FULL TOP AND BOTTOM COIL OF THE
SPRING MUST BE CAPTURED BY THE JAWS OF
THE COIL SPRING COMPRESSOR.
(9) Inspect the strut for any binding of the strut
shaft over the full stroke of the shaft.
(10) Inspect the strut mount and the upper spring
seat assembly (Fig. 74) for any of the following con-
ditions:
²Mount for cracks and distortion and retaining
studs for any sign of damage.
²Severe deterioration of rubber isolator,
Fig. 70 Strut Mount
Fig. 71 Upper Spring Seat Assembly
Fig. 72 Jounce Bumper Removal
Fig. 73 Strut Assembly Coil Spring
Fig. 74 Upper Spring Mount And Isolator Assembly
Components
PLSUSPENSION 2 - 31
DISASSEMBLY AND ASSEMBLY (Continued)

²Binding strut assembly pivot bearing. If pivot
bearing is replaced it is to be installed with the white
side of bearing facing up (Fig. 74).
²Inspect dust shield for rips and/or deterioration.
²Inspect jounce bumper for cracks and signs of
deterioration.
(11) Replace any components of the strut assembly
found to be worn or defective during the inspection,
before assembling the strut.
ASSEMBLE
(1) Clamp the strut assembly in a vise, with the
strut in a vertical position.When clamping the
strut assembly in the vise, do not clamp strut
using the body of the strut only by strut clevis
bracket (Fig. 67).
(2) Install the compressed coil spring onto the
strut. Coil spring is to be installed with smaller coil
down, so spring correctly seats on strut assembly
(Fig. 73).
(3) Install jounce bumper on the strut shaft (Fig.
72).
(4) Install dust shield, pivot bearing and upper
spring seat as an assembly on the strut (Fig. 71).
(5) Position upper spring seat alignment notch
with clevis bracket on strut assembly.
(6) Install strut mount on strut assembly (Fig. 70)
and the strut mount retaining nut on the shaft of the
strut assembly.
WARNING: THE FOLLOWING 2 STEPS MUST BE
COMPLETELY DONE BEFORE SPRING COMPRES-
SOR, SPECIAL TOOL C-4838 IS RELEASED FROM
THE COIL SPRING.
(7) Install Socket, Strut Nut, Special Tool L-4558A
(or L-4558) on the strut shaft retaining nut (Fig. 69).
Then install a 10 mm socket through the center of
the socket and on the hex of the strut shaft (Fig. 69).
While holding strut shaft from turning, torque strut
shaft retaining nut to 75 N´m (55 ft. lbs.).
(8) Equally loosen both Spring Compressors, Spe-
cial Tool C-4838 until top coil of spring is fully seated
against upper spring seat and strut mount. Then
relieve all tension from spring compressors and
remove spring compressors from strut assembly
spring.
BALL JOINT
DISASSEMBLE
(1) Using a screw driver or other suitable tool, pry
seal boot off of ball joint assembly (Fig. 75).
(2) Position Receiving Cup, Special Tool 6758 to
support lower control arm while receiving ball joint
assembly (Fig. 76). Install Remover/Installer, Special
Tool 6804 in top of ball joint assembly (Fig. 76).(3) Using arbor press, press ball joint assembly
completely out of lower control arm.
ASSEMBLE
CAUTION: When installing ball joint in its mount-
ing hole in lower control arm, position ball joint so
notch in ball joint stud is facing the front lower con-
trol arm bushing. This will ease assembly of ball
joint to steering knuckle when attempting to install
pinch bolt.
(1) By hand, position ball joint assembly into ball
joint bore of lower control arm. Be sure ball joint
assembly is not cocked in the bore of the control arm,
this will cause binding of the ball joint assembly,
when being pressed into lower control arm.
(2) Position assembly in an arbor press with
Receiving Cup, Special Tool 6758 supporting lower
control arm (Fig. 77). Then install Remover/Installer,
Special Tool 6804 on the bottom of the ball joint
assembly (Fig. 77).
Fig. 75 Ball Joint Seal Boot Removal
Fig. 76 Removing Ball Joint From Lower Control
Arm
2 - 32 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Carefully align all pieces. Using the arbor
press apply pressure against ball joint assembly (Fig.
77), until ball joint is fully seated against bottom sur-
face of lower control arm. Do not apply excessive
pressure against ball joint and lower control arm.
(4) Install aNEWball joint assembly sealing boot
on ball joint assembly. Install sealing boot as far as
possible on ball joint assembly.
CAUTION: Do not use an arbor press to install the
sealing boot on the lower control arm ball joint
assembly. Damage to the sealing boot can occur do
to excessive pressure applied to sealing boot when
being installed.
(5) Position Receiving Cup, Special Tool 6758 over
sealing boot so it is aligned properly with bottom
edge of sealing boot (Fig. 78). Apply pressureBY
HANDto special tool 6758, until sealing boot is
pressed squarely against top surface of lower control
arm.
LOWER CONTROL ARM FRONT ISOLATOR
BUSHING
DISASSEMBLY
To perform the removal and replacement of the
lower control arm front isolator bushing, the lower
control arm must be removed from the vehicle.
(1) Remove the lower control arm assembly from
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required removal procedure.
(2) Mount Remover/Installer, Special Tool
C-4212-F in a vise (Fig. 79). Install Bushing
Remover, Special Tool 6804 and Bushing Receiver,
Special Tool 6758 on Special Tool C-4212-F (Fig. 79).
(3) Install lower control arm on Special Tools
assembled for removal of the front isolator bushing
as shown in (Fig. 80). Be sure Special Tool 6758 is
square on lower control arm and Special Tool 6804 is
positioned correctly on isolator bushing.
(4) Tighten screw on Remover/Installer Special
Tool C-4212-F to press front bushing out of lower
control arm.
ASSEMBLY
(1) Mount Installer Cup, Special Tool C-4212-F on
Remover/Installer, Special Tool C-4212-F (Fig. 81).
Then mount Bushing Installer, Special Tool 6810 on
screw portion of Remover/Installer Special Tool
C-4212-F (Fig. 81).
(2) Start front bushing into lower control armby
hand, making sure it is square with its mount-
ing hole in the lower control arm.Bushing is to
be installed in lower control arm from the machined
surface side of lower control arm bushing hole (Fig.
82).
(3) Install lower control arm as shown in (Fig. 83)
on Special Tools assembled for installing front isola-
Fig. 77 Installing Ball Joint In Lower Control Arm
Fig. 78 Ball Joint Seal Boot Installation
Fig. 79 Special Tools Assembled For Removing
Front Bushing
PLSUSPENSION 2 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

tor bushing into lower control arm. Be sure SpecialTool C-4212-F is square on lower control arm and
Special Tool 6810 is positioned correctly on isolator
bushing.
(4) Tighten screw on Remover/Installer Special
Tool C-4212-F pressing front bushing into lower con-
trol arm. Continue pressing front bushing into lower
control arm until special tool 6810 is sitting flush on
the machined surface of the lower control arm (Fig.
84). This will correctly position front bushing in
lower control arm.
(5) Install the lower control arm assembly back on
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required installation procedure.
LOWER CONTROL ARM REAR ISOLATOR BUSHING
DISASSEMBLY
Removal and installation of the lower control arm
rear isolator bushing is done using an arbor press.
Fig. 80 Removing Front Bushing From Lower
Control Arm
Fig. 81 Special Tools Assembled For Installing
Front Bushing
Fig. 82 Installation Direction Of Lower Control Arm
Front Bushing
Fig. 83 Front Bushing Installation
Fig. 84 Installation Position Of Front Lower Control
Arm Bushing
2 - 34 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

Do not attempt to use a different procedure from that
below for the removal and replacement of rear lower
control arm bushing.
(1) Remove the lower control arm assembly from
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required removal procedure.
(2) Position lower control arm in an arbor press
supported at rear bushing using Receiver Cup, Spe-
cial Tool 6756 (Fig. 85). Position Remover/Installer,
Special Tool 6758 on top of rear control arm bushing
(Fig. 85).
(3) Press isolator bushing out of the lower control
arm.
ASSEMBLY
(1) Install the rear bushing into the lower control
arm in the direction indicated in (Fig. 86).Rear
bushing must be positioned in lower control
arm with the void in the bushing pointing
toward the compression strut of the lower con-
trol arm as shown in (Fig. 86).
(2) Place lower control arm in an arbor press sup-
ported at rear bushing hole using Receiver Cup, Spe-
cial Tool 6756 (Fig. 87). Correctly position Remover/
Installer, Special Tool 6760 on top of rear control arm
bushing (Fig. 87).
(3) Press rear bushing into lower control arm,
until flange on bushing is flush with machined sur-
face of lower control arm (Fig. 88).
(4) Install the lower control arm assembly back on
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required installation procedure.
Fig. 85 Special Tools Assembled For Removing
Rear Bushing
Fig. 86 Correct Installation Of Bushing In Lower
Control Arm
Fig. 87 Rear Bushing Installation
Fig. 88 Correctly Installed Rear Bushing
PLSUSPENSION 2 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION PACKAGE
SUSPENSION
The front struts used on a vehicle equipped with
the competition package are adjustable. The adjust-
able front struts use a unique strut shaft with an
adjustment rod through the center of it (Fig. 89). The
adjustment rod is used to adjust the compression
dampening of the strut.
The compression dampening of the strut is adjusted
using the adjustment knob (Fig. 90) which is supplied
with the vehicle at the time of purchase. The adjust-
ment is done by inserting the flat on the end of the
adjustment rod into the grove on the adjustment knob
(Fig. 91). The compression dampening is increased by
rotating the adjustment knob in a counterclockwise
direction and decresed by rotating the adjustment knob
in a clockwise direction (Fig. 90).
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
McPHERSON STRUT:
To Shock Tower Attaching
Nuts....................34N´m(300 in. lbs.)
Clevis Bracket To
Steering Knuckle...........54N´m(40ft.lbs.)
+ 90É Turn
Strut Shaft Nut..............74N´m(55ft.lbs.)
STEERING KNUCKLE:
Ball Joint Stud To
Steering Knuckle Nut/Bolt. . . .95 N´m (70 ft. lbs.)
Disc Brake Caliper Bolts.......22N´m(16ft.lbs.)
STEERING GEAR:
To Crossmember
Attaching Bolts.............68N´m(50ft.lbs.)
Tie Rod End Adjusting
Sleeve Nut................75N´m(55ft.lbs.)
Tie Rod End To Steering
Knuckle Nut...............54N´m(40ft.lbs.)
FRONT SUSPENSION CROSSMEMBER:
To Body Attaching Bolts......163 N´m (120 ft. lbs.)
Lower Control Arm Pivot
Bolt....................163 N´m (120 ft. lbs.)
STABILIZER BAR:
Bushing Retainer To
Crossmember Bolts..........28N´m(21ft.lbs.)
To Control Arm Attaching
Link Nut..................28N´m(21ft.lbs.)
HUB AND BEARING:
Front Stub Axle To Hub
Bearing Nut.............183 N´m (135 ft. lbs.)
Wheel Mounting
LugNut...........109-150 N´m (80-110 ft. lbs.)
Fig. 89 Adjustable Front Strut
Fig. 90 Adjustable Strut Adjustment Knob
Fig. 91 Adjustment Knob Installation
2 - 36 SUSPENSIONPL

SPECIAL TOOLS
FRONT SUSPENSION
Socket/Holder Front Strut Nut L-4558A
Compressor Strut Coil Spring C-4838
Press Remover/Installer C-4212-F
Remover Lower Control Arm Small Bushing And
Ball Joint 6804
Installer Ball Joint 6758
Installer Lower Control Arm Small Bushing 6810
Adapter Ball Joint Remover/Installer C-4212-3
Receiver Ball Joint 6756
PLSUSPENSION 2 - 37

Remover/Installer Lower Control Arm Bushing
6644-2
Installer Ball Joint 6760
Remover Tie Rod End MB-990635
Splitter Bearing 1130
Remover Ball Joint MB-990799
Installer Bearing 5052
Installer Adapter C-4698-2
Remover Lower Ball Joint C-4150A
Installer Bearing Cup 6522
2 - 38 SUSPENSIONPL
SPECIAL TOOLS (Continued)

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 39
DESCRIPTION AND OPERATION
COIL SPRING........................... 41
COMPETITION PACKAGE SUSPENSION...... 41
KNUCKLE............................. 41
LATERAL LINKS AND TENSION STRUTS...... 41
REAR SUSPENSION..................... 39
STABILIZER BAR........................ 41
STRUT................................ 41
DIAGNOSIS AND TESTING
KNUCKLE............................. 42
LATERAL LINKS......................... 42
STABILIZER BAR AND BUSHINGS........... 43
STABILIZER BAR ATTACHING LINKS......... 43
STRUT INSPECTION (ON VEHICLE)......... 42
TENSION STRUT........................ 42
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT................ 43REMOVAL AND INSTALLATION
COIL SPRING........................... 44
KNUCKLE............................. 46
LATERAL LINKS......................... 48
STABILIZER BAR........................ 45
STRUT ASSEMBLY...................... 43
DISASSEMBLY AND ASSEMBLY
STABILIZER BAR BUSHINGS............... 53
STRUT ASSEMBLY...................... 50
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 53
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS...................... 54
SPECIAL TOOLS
REAR SUSPENSION..................... 54
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: Only frame contact or wheel lift hoisting
equipment can be used on vehicles having a fully
independent rear suspension. Vehicles with inde-
pendent rear suspension can not be hoisted using
equipment designed to lift a vehicle by the rear
axle. If this type of hoisting equipment is used dam-
age to rear suspension components will occur.
NOTE: If a rear suspension component becomes
bent, damaged or fails, no attempt should be made
to straighten or repair it. Always replace with a new
component.
DESCRIPTION AND OPERATION
REAR SUSPENSION
The rear suspension system used on this vehicle is
a fully independent type rear suspension system (Fig.
1).A forged rear knuckle is bolted to each rear strut.
The movement of the rear knuckle is controlled lat-
erally using lateral links going from the front and
rear of the knuckle to the rear crossmember. Fore
and aft movement of the knuckle is controlled by a
tension strut.
The lateral links and tension strut have rubber iso-
lator bushings at each end. The lateral links are
attached to the rear crossmember and knuckle, using
a common bolt and nut assembly at each end. The
tension strut bolts to the bottom of the knuckle and
to a bracket attached to the floor pan of the vehicle.
The lateral links, tension strut and spindle are
normally replaced only when the part has been dam-
aged or when the vehicle has been involved in an
accident. If a suspension part has been damaged, be
sure to check the underbody dimensions of the car. If
the underbody dimensions are not correct, the frame
of the vehicle must be straightened, before replace-
ment suspension components are installed.
PLSUSPENSION 2 - 39