boot DODGE NEON 1999 Service User Guide

CAUTION: Seal must not be dimpled, stretched, or
out±of±shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
CAUTION: The following positioning procedure
determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing
boot to inner tripod joint housing. If this procedure
is not done prior to clamping sealing boot to tripod
joint housing, boot durability can be adversely
affected.
CAUTION: When venting the inner tripod joint
assembly, use care so inner tripod sealing boot
does not get punctured or, in any other way, dam-
aged. If sealing boot is punctured or damaged while
being vented, the sealing boot can not be used.
Fig. 29 Spider Assembly Retaining Snap Ring
Installed
Fig. 30 Installing Tripod Housing on Spider
Assembly
Fig. 31 Crimping Tool Installed on Sealing Boot
Clamp
Fig. 32 Sealing Boot Retaining Clamp Installed
PLDIFFERENTIAL AND DRIVELINE 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

(9) Insert a trim stick between the tripod joint and
the sealing boot to vent inner tripod joint assembly
(Fig. 33).When inserting trim stick between tri-
pod housing and sealing boot, ensure trim stick
is held flat and firmly against the tripod hous-
ing. If this is not done, damage to the sealing
boot can occur.If inner tripod joint has a Hytrel
(hard plastic) sealing boot, be sure trim stick is
inserted between soft rubber insert and tripod hous-
ing, and not the hard plastic sealing boot and soft
rubber insert.
(10) With trim stick inserted between sealing boot
and tripod joint housing, position inner tripod joint
on driveshaft until correct sealing boot edge to edge
length is obtained for type of sealing boot material
being used (Fig. 34) (Fig. 35). Then remove the trim
stick.
(11) Clamp tripod joint sealing boot to tripod joint
using required procedure for type of boot clamp
application. If seal boot uses crimp type boot clamp,clamp sealing boot onto tripod housing using crimper,
Special Tool C-4975-A. Place crimping tool C- 4975-A
over bridge of clamp (Fig. 36). Tighten nut on crimp-
ing tool C- 4975-A until jaws on tool are closed com-
pletely together, face±to±face (Fig. 37).
(12) If seal boot uses low profile latching type boot
clamp, clamp sealing boot onto tripod housing using
clamp locking tool, Snap-OntYA3050 (or an equiva-
lent). Place prongs of clamp locking tool in the holes
of the clamp (Fig. 38). Squeeze tool together until top
band of clamp is latched behind the two tabs on
lower band of clamp (Fig. 39).
(13) Install the driveshaft requiring boot replace-
ment back on the vehicle. See Servicing Driveshaft in
this section for the required driveshaft installation
procedure.
Fig. 33 Trim Stick Inserted for Venting Tripod Joint
Fig. 34 Sealing Boot End to End Length with Hytrel
Boot
Fig. 35 Sealing Boot End to End Length with
Silicone Boot
Fig. 36 Crimping Tool Installed on Sealing Boot
Clamp
3 - 12 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTER C/V JOINT SEAL BOOT
REMOVAL
To remove outer C/V joint sealing boot from a
driveshaft for replacement, the driveshaft assembly
must be removed from the vehicle. See Servicing
Driveshaft in this section for the required driveshaft
removal and replacement procedure.
(1) Remove driveshaft assembly requiring boot
replacement from vehicle. See Servicing Driveshaft in
this section for the required driveshaft removal pro-
cedure.
(2) Remove large boot clamp retaining C/V joint
sealing boot to C/V joint housing (Fig. 40) and dis-
card. Remove small clamp that retains outer C/V
joint sealing boot to interconnecting shaft and dis-
card. Remove sealing boot from outer C/V joint hous-
ing and slide it down interconnecting shaft.
(3) Wipe away grease to expose outer C/V joint and
interconnecting shaft.
(4) Remove outer C/V joint from interconnecting
shaft using the following procedure: Support inter-
connecting shaft in a viseequipped with protec-
tive caps on jaws of vise to prevent damage to
interconnecting shaft.Then, using asoft±faced
hammer,sharply hit the end of the C/V joint housing
to dislodge housing from internal circlip on intercon-
necting shaft (Fig. 41). Then slide outer C/V joint off
end of interconnecting shaft, joint may have to be
tapped off shaft using asoft±facedhammer.
Fig. 37 Sealing Boot Retaining Clamp Installed
Fig. 38 Clamping Tool Installed on Sealing Boot
Clamp
Fig. 39 Sealing Boot Clamp Correctly Installed
Fig. 40 Outer C/V Joint Seal Boot Clamps
PLDIFFERENTIAL AND DRIVELINE 3 - 13
DISASSEMBLY AND ASSEMBLY (Continued)

(5) Remove large circlip (Fig. 42) from the inter-
connecting shaft before attempting to remove outer
C/V joint sealing boot.
(6) Slide failed sealing boot off interconnecting
shaft.
(7) Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of
excessive wear.If any parts show signs of exces-
sive wear, the driveshaft assembly will require
replacement. Component parts of these drive-
shaft assemblies are not serviceable.
INSTALLATION
(1) Slide new sealing boot to interconnecting shaft
retaining clamp onto interconnecting shaft. Slide the
outer C/V joint assembly sealing boot onto the inter-
connecting shaft (Fig. 43).Seal boot MUST be
positioned on interconnecting shaft so the
raised bead on the inside of the seal boot is in
groove on interconnecting shaft.(2) Align splines on interconnecting shaft with
splines on cross of outer C/V joint assembly and start
outer C/V joint onto interconnecting shaft.
(3) Install outer C/V joint assembly onto intercon-
necting shaft by using asoft±facedhammer and
tapping end of stub axle (with nut installed) until
outer C/V joint is fully seated on interconnecting
shaft (Fig. 44).
Fig. 41 Outer C/V Joint Removal from
Interconnecting Shaft
Fig. 42 Circlip Removal from Interconnecting Shaft
Fig. 43 Sealing Boot Installation on Interconnecting
Shaft
Fig. 44 Outer C/V Joint Installation on
Interconnecting Shaft
3 - 14 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Outer C/V joint assembly must be installed on
interconnecting shaft until cross of outer C/V joint
assembly is seated against circlip on interconnecting
shaft (Fig. 45).
(5) Distribute 1/2 the amount of grease provided in
seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into outer C/V joint
assembly housing. Put the remaining amount into
the sealing boot.
(6) Install outer C/V joint sealing boot to intercon-
necting shaft clamp evenly on sealing boot.
(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow-
ing procedure. Place crimping tool C- 4975-A over
bridge of clamp (Fig. 46). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com-
pletely together, face to face (Fig. 47).CAUTION: Seal must not be dimpled, stretched, or
out±of±shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Position outer C/V joint sealing boot into its
retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp evenly
on sealing boot.
(9) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975-A and the fol-
lowing procedure. Place crimping tool C- 4975-A over
bridge of clamp (Fig. 48). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com-
pletely together, face to face (Fig. 49).
Fig. 45 Outer C/V Joint Correctly Installed on
Interconnecting Shaft
Fig. 46 Crimping Tool Installed on Sealing Boot
Clamp
Fig. 47 Sealing Boot Retaining Clamp Installed
Fig. 48 Crimping Tool Installed on Sealing Boot
Clamp
PLDIFFERENTIAL AND DRIVELINE 3 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

(10) Install the driveshaft requiring boot replace-
ment back on the vehicle. See Servicing Driveshaft in
this section for the required driveshaft installation
procedure.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Caliper To Knuckle Bolt........31N´m(23ft.lbs.)
Driveshaft Nut.............183 N´m (135 ft. lbs.)
Front Wheel Lug Nuts.......135 N´m (100 ft. lbs.)
Knuckle To Ball Joint Bolt......95N´m(70ft.lbs.)
Tie Rod End To Knuckle........61N´m(45ft.lbs.)
SPECIAL TOOLS
DRIVESHAFT
Fig. 49 Sealing Boot Retaining Clamp Installed
Tie Rod Remover MB-990635
Boot Clamp Installer C-4975A
3 - 16 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

All the front brake forces generated during braking
of the vehicle is taken up directly by the steering
knuckles of the vehicle.
The caliper is a one piece casting with the inboard
side containing a single piston cylinder bore.
The front disc brake caliper piston (Fig. 2), is man-
ufactured from a phenolic compound. The outside
diameter of the caliper piston is 54 mm.
A square cut rubber piston seal is located in a
machined groove in the caliper cylinder bore. This
provides a hydraulic seal between the piston and the
cylinder wall (Fig. 4).
A rubber dust boot is installed in the cylinder bore
opening and in a groove in the piston (Fig. 4). This
prevents contamination in the bore area.As front disc brake linings wear, master cylinder
reservoir brake fluid level will drop. Fluid level
should be checked after replacing linings.
Front disc brakes are equipped with an audible
wear indicator (Fig. 2) on the outboard brake pad.
This sensor emits a sound when the brake lining
may need inspection and/or replacement.
Fig. 1 Front Disc Brake Caliper Assembly
Fig. 2 Front Disc Brake Caliper (Exploded View)
Fig. 3 Front Disc Brake Caliper Mounting
PLBRAKES 5 - 3
DESCRIPTION AND OPERATION (Continued)

(6) Remove brake rotor from hub by pulling it
straight off the wheel mounting studs (Fig. 63).
(7) Remove outboard brake shoe by prying the
shoe retaining clip over raised area on caliper. Then
slide the brake shoe down and off the caliper (Fig.
64).
(8) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip is out of the cavity
in the piston. (Fig. 65).
CALIPER INSPECTION
Check caliper for piston seal leaks (brake fluid in
and around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
or fluid leak is visible, disassemble caliper and
install a new seal and boot, (and piston if scored).
Refer to Caliper Disassembly And Re-Assembly Pro-
cedures in Disc Brake Caliper Service in this section
of the service manual.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.Replace if they are damaged, dry, or found to be brit-
tle. Refer to Guide Pin Bushing Service in Disc
Brake Caliper Service in this section of the service
manual.
INSTALL
(1) Completely retract caliper piston back into pis-
ton bore of caliper. This is required for caliper instal-
lation with new brake shoe assemblies.
(2) Lubricate both steering knuckle abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or equivalent.
(3) Install the front rotor on the hub, making sure
it is squarely seated on face of hub (Fig. 63).
(4) Remove the protective paper from the noise
suppression gasket on both the inner and outer brake
shoes (if equipped).
NOTE: Note: The inboard and outboard brake
shoes are not common (Fig. 66).
Fig. 62 Storing Caliper
Fig. 63 Removing/Installing Brake Rotor
Fig. 64 Removing Outboard Brake Shoe
Fig. 65 Removing Inboard Brake Shoe
PLBRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)

from adapter, and then lifting caliper assembly off
lower machined abutment on adapter (Fig. 75).
(5) Support caliper assembly firmly from rear strut
to prevent weight of caliper from damaging the flex-
ible brake hose (Fig. 76).
(6) Remove rear rotor from hub/bearing assembly
(Fig. 77). Then inspect drum-in-hat parking brake
shoes and parking brake braking surface on rotor for
any signs of excessive wear or damage. Replace park-
ing brake shoes if required.
(7) Remove outboard brake pad from caliper by
prying brake pad retaining clip over raised area oncaliper. Then slide brake pad down and off the cali-
per (Fig. 78).
(8) Pull inboard brake pad away from caliper pis-
ton, until retaining clip is free from cavity in piston.
(Fig. 79).
CALIPER INSPECTION
Check caliper for piston seal leaks (brake fluid in
and around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
Fig. 75 Removing/Installing Caliper Assembly From
Adapter
Fig. 76 Storing Caliper
Fig. 77 Rear Brake Rotor
Fig. 78 Outboard Brake Shoe
PLBRAKES 5 - 33
REMOVAL AND INSTALLATION (Continued)

or fluid leak is visible, disassemble caliper and
install a new seal and boot, (and piston if scored).
Refer to Caliper Disassembly And Re-Assembly Pro-
cedures in Disc Brake Caliper Service in this section
of the service manual.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brit-
tle. Refer to Guide Pin Bushing Service in Disc
Brake Caliper Service in this section of the service
manual.
INSTALL
(1) Completely retract the caliper piston back into
the piston bore of the caliper assembly. This is
required for caliper installation when new brake pad
assemblies are installed on caliper.
(2) Lubricate both adapter abutments with a lib-
eral amount of MopartMultipurpose Lubricant, or
equivalent.
(3) Install rear rotor on the hub making sure it is
squarely seated on face of hub (Fig. 77).
(4) Remove protective paper from noise suppres-
sion gasket on both inner and outer brake pad
assemblies (if equipped).
(5) Install new inboard brake shoe assembly into
caliper piston by firmly pressing into piston bore
with thumbs (Fig. 79).Be sure inboard brake
shoe assembly is positioned squarely against
face of caliper piston.
(6) Slide new outboard brake pad assembly onto
the caliper assembly (Fig. 78). Be sure retaining clip
is squarely seated in the depressed areas on the cal-
iper.
CAUTION: Use care when installing caliper assem-
bly onto adapter, so the guide pin bushings andsleeves do not get damaged by the mounting
bosses on adapter.
(7) Carefully lower caliper and brake shoe assem-
blies over braking disc (rotor) reversing the required
removal procedure (Fig. 75). Make sure that caliper
guide pin bolts, bushings and sleeves are clear of the
adapter bosses.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(8) Install caliper assembly guide pin bolts into
adapter and tighten (Fig. 74). Then torque both guide
pin bolts to 22 N´m (192 in. lbs.).
(9) Install the wheel and tire assembly.
(10) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(11) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
REAR BRAKE DRUM
REMOVE
Further clearance can be obtained by backing off
the brake automatic adjuster screw. Remove rubber
plug from top of brake support plate. Rotate auto-
matic adjuster screw assembly with an upward
motion, using a medium size screwdriver.
See adjusting rear service brakes in the Service
Adjustments section in this group of the service man-
ual for the specific adjustment procedure.
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped).
(4) Remove rear brake drum from rear hub/bear-
ing assembly (Fig. 80).
(5) Inspect brake linings for wear, shoe alignment
and contamination.
INSTALL
(1) Install rear brake drum assembly on rear hub
and bearing assembly.
(2) Install the wheel and tire assembly.
Fig. 79 Removing Inboard Brake Shoe
5 - 34 BRAKESPL
REMOVAL AND INSTALLATION (Continued)