DODGE NEON 1999 Service Repair Manual

(4) Remove bolts holding fascia bracket to lower
quarter panels.
(5) Separate fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install bolts holding fascia bracket to lower
quarter panels.
(3) Install push±in fasteners holding fascia to bot-
tom of rear bumper reinforcement (Fig. 3).
(4) Install bolts holding fascia to tail closure panel.
REAR BUMPER REINFORCEMENT
REMOVAL
(1) Remove rear fascia.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Remove nuts holding reinforcement to rear clo-
sure panel (Fig. 4).(4) Separate bumper reinforcement from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 2 Front Bumper ReinforcementFig. 3 Rear Bumper Fascia
Fig. 4 Rear Bumper Reinforcement
13 - 2 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

FRAMES
INDEX
page page
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER....... 3
SPECIFICATIONS
STRUCTURAL DIMENSIONS................ 4TORQUE SPECIFICATIONS................ 10
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER
WARNING: IF SUSPENSION CROSSMEMBER IS
REPLACED DUE TO COLLISION DAMAGE, INSPECT
THE STEERING COLUMN TO STEERING GEAR
COUPLING FOR DAMAGE. REFER TO GROUP 19,
STEERING FOR INSTRUCTIONS.
Before removing front suspension crossmem-
ber, index mark location of crossmember on
frame to aid installation.
The front suspension crossmember must be prop-
erly installed to achieve design camber, caster set-
tings and wheel stagger. The crossmember can be
installed out of position on the frame rails due to its
design. Bolts and cage nuts hold the rear of the
crossmember to the frame torque boxes. Bolts and
J-nuts hold the front of the crossmember to the
frame rails. No designed in locating device is used to
position the crossmember in the vehicle. Before
removing the crossmember mark the frame torque
box around the rear mounting location to aid instal-
lation. A crossmember that is removed during service
must be installed in the same position from which it
was removed. To verify that crossmember is in the
proper position, refer to the dimensions provided.
Front end dimensions are gauged from the principal
locating point (PLP) holes located under the frame
torque boxes rearward of the front wheels. After
removal and installation of the crossmember is per-
formed, verify that front suspension alignment is
within specifications. If camber, caster settings and
wheel stagger is not within specifications, loosen and
reposition crossmember to bring suspension within
specifications. Refer to Group 2, Front Suspension
and Driveshaft for additional information.
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Using a suitable marking device, mark the out-
line of the suspension crossmember on the frame
torque box around the rear mounting location.(3) Remove front wheels from vehicle.
(4) Remove pinch bolts holding front ball joints to
spindles.
(5) Separate ball joints from spindles.
(6) Position a suitable lifting device under the
crossmember.
(7) Remove bolts holding suspension crossmember
to frame rails above lower control arms (Fig. 1).
(8) Remove bolts holding crossmember to frame
torque boxes and allow front of crossmember to
swing down.
(9) Remove bolts holding steering gear to cross-
member.
(10) Separate steering gear from crossmember.
(11) Tie steering gear to a suitable structure above
to support gear after crossmember is removed.
(12) Separate front suspension crossmember from
vehicle.
INSTALLATION
If a new crossmember is to be installed, transfer
stabilizer bar and lower control arms from original
crossmember. Refer to Group 2, Suspension and
Driveshaft for proper procedures.
(1) Place front suspension crossmember in position
on vehicle.
(2) Remove tie device supporting steering gear.
Fig. 1 Front Suspension Crossmember
PLFRAME AND BUMPERS 13 - 3

(3) Place steering gear in position on crossmember.
(4) Install bolts to hold steering gear to crossmem-
ber.
(5) Position lifting device under the crossmember.
(6) Lift crossmember to frame rails.
(7) Engage bolts to hold crossmember rear mounts
into cage nuts in the frame torque boxes. Do not
tighten bolts.
(8) Install bolts to hold crossmember to frame rails
above lower control arms.
(9) Lower and remove lifting device.
(10) Align crossmember to index marks. Verify
that crossmember is at the specified dimensions from
the PLPs (Fig. 2).
(11) Tighten bolts to hold suspension crossmember
to frame rails and torque boxes.
(12) Insert ball joints into spindles.
(13) Install pinch bolts to hold front ball joints to
spindles.(14) Install front wheels on vehicle.
(15) Lower vehicle and verify front suspension
alignment. If camber, caster settings and wheel stag-
ger is not within specifications, loosen and reposition
crossmember to bring suspension within specifica-
tions. Refer to Group 2, Front Suspension and Drive-
shaft for additional information.
SPECIFICATIONS
STRUCTURAL DIMENSIONS
Structural dimensions are listed in metric mea-
surements. All dimensions are from center to center
of Principal Locating Point (PLP), or from center to
center of PLP and fastener location (Fig. 3), (Fig. 4),
(Fig. 5), (Fig. 6), (Fig. 7), and (Fig. 8).
Fig. 2 Forward Frame and Suspension Crossmember
13 - 4 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Engine Compartment Top View
PLFRAME AND BUMPERS 13 - 5
SPECIFICATIONS (Continued)

Fig. 4 Engine Compartment Side and Bottom View
13 - 6 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

Fig. 5 Rear Frame Section Side and Bottom View
PLFRAME AND BUMPERS 13 - 7
SPECIFICATIONS (Continued)

Fig. 6 Door and Windshield OpeningsÐ4 Door
13 - 8 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

Fig. 7 Door and Windshield OpeningsÐ2 Door
PLFRAME AND BUMPERS 13 - 9
SPECIFICATIONS (Continued)

TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Bumper Reinforcement
Nut.....................156 N´m (115 ft. lbs)
Rear Bumper Reinforcement
Nut.....................156 N´m (115 ft. lbs)
Front Crossmember To Body
Mounting Bolts...........163 N´m (120 ft. lbs)
Fig. 8 Rear Window and Trunk Openings
13 - 10 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

FRAME AND BUMPERS
CONTENTS
page
FRAME................................ 1
FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT TOW HOOK BRACKET............. 1REAR TOW HOOK BRACKET.............. 1
REMOVAL AND INSTALLATION
FRONT TOW HOOK BRACKET
REMOVAL
(1) Hoist and support vehicle. Refer to Group 0,
Lubrication and Maintenance, for proper lifting pro-
cedures.
(2) Remove bolts holding front tow hook bracket to
lower radiator crossmember.
(3) Separate front tow hook bracket from vehicle.
INSTALLATION
(1) Position front tow hook bracket to vehicle.
(2) Install bolts to hold front tow hook bracket to
lower radiator crossmember.(3) Lower vehicle.
REAR TOW HOOK BRACKET
REMOVAL
(1) Hoist and support vehicle. Refer to Group 0,
Lubrication and Maintenance, for proper lifting pro-
cedure.
(2) Remove bolts holding rear tow hook bracket to
rear frame rail (Fig. 2).
(3) Separate rear tow hook bracket from vehicle.
INSTALLATION
(1) Position rear tow hook bracket on vehicle.
(2) Install bolts to hold rear tow hook bracket to
rear frame rail.
(3) Lower vehicle.
Fig. 1 Front Tow Hook BracketFig. 2 Rear Tow Hook Bracket
PLFRAME AND BUMPERS 13 - 1