maintenance DODGE NEON 1999 Service User Guide

(2) Loosen hub nut while vehicle is on the floor
with the brakes applied (Fig. 16).The hub and
driveshaft are splined together through the
knuckle (bearing) and retained by the hub nut.
(3) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(4) Remove the front tire and wheel.
(5) Remove front disc brake caliper to steering
knuckle attaching bolts (Fig. 17).
(6) Remove the disc brake caliper from the steer-
ing knuckle. Caliper is removed by first lifting bot-
tom of caliper away from steering knuckle, and then
removing top of caliper out from under steering
knuckle (Fig. 18).
(7)
Support brake disc brake caliper assembly using a
wire hook and not by hydraulic hose (Fig. 19).
(8) Remove the rotor from the front hub/bearing
(Fig. 20).
Fig. 16 Loosening Front Hub Retaining Nut
Fig. 17 Disc Brake Caliper Attaching Bolts
Fig. 18 Brake Caliper Removal
Fig. 19 Supporting Brake Caliper
Fig. 20 Remove /Install Rotor
2 - 18 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(8) Install the disc brake caliper to steering
knuckle attaching bolts (Fig. 17). Tighten the caliper
attaching bolts to a torque of 31 N´m (23 ft. lbs.).
(9) Clean all foreign matter from the threads of
the outer C/V joint stub axle (Fig. 29). Install hub
nut onto threads of stub axle and tighten nut.
(10) With vehicle brakes applied to keep braking
disc from turning, tighten hub nut to a torque of 183
N´m (135 ft. lbs.) (Fig. 30).
(11) Install front wheel and tire assembly. Install
front wheel lug nuts and torque to 135 N´m (100 ft.
lbs.).
(12) Lower vehicle.
(13) Install the spring washer, hub nut lock, and
new cotter pin (Fig. 31). Wrap cotter pin prongs
tightly around the hub nut lock (Fig. 32).
(14) Set front Toe on vehicle to required specifica-
tion. Use procedure listed under Wheel Alignment, in
the Front Suspension Service Procedures section of
this service manual.
LOWER CONTROL ARM
REMOVE
(1)Raise vehicle on jack stands or centered on a frame
contact type hoist. See Hoisting in the Lubrication and
Maintenance section of this manual for the required lifting
procedure to be used. Remove wheel and tire assembly
from side of vehicle requiring service to lower control arm.
(2) Remove the steering knuckle to ball joint ball
stud, clamping nut and bolt (Fig. 33).
Fig. 29 Front Hub To Stub Shaft Nut
Fig. 30 Torquing Front Hub Nut
Fig. 31 Spring Washer, Nut Lock, And New Cotter
Pin
Fig. 32 Cotter Pin Correctly Installed
Fig. 33 Control Arm To Steering Knuckle
Attachment
PLSUSPENSION 2 - 21
REMOVAL AND INSTALLATION (Continued)

(4) Assemble stabilizer bar to lower control arm
link assemblies and bushings as shown in (Fig. 38).
(5) Rotate stabilizer bar into position, installing
the stabilizer bar link assemblies into the lower con-
trol arms. Then install the top stabilizer bar link
bushings and nuts (Fig. 39).DO NOT TIGHTEN
LINK ASSEMBLIES AT THIS TIME
(6) Lower vehicle so suspension is supporting the
total weight of the vehicle.
(7) Torque the stabilizer bar to lower control arm
link assemblies (Fig. 39) to 28 N´m (21 ft. lbs.).
(8) Torque the 2 stabilizer bar bushing retainer, to
crossmember attaching bolts (Fig. 35) to 28 N´m (21
ft. lbs.).STABILIZER BAR
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove nuts and stabilizer bar attaching link
assemblies from the front lower control arms (Fig.
40).
(3) Remove bolts at front crossmember to stabilizer
bar bushing retainers (Fig. 41). Then remove bushing
retainers, stabilizer bar, and bushings from front
crossmember.
Fig. 38 Assembled Stabilizer Bar Link And Bushings
Fig. 39 Installed Stabilizer Bar To Lower Control
Arm Attaching Link
Fig. 40 Sabilizer Bar To Lower Control Arm
Attaching Links
Fig. 41 Front Stabilizer Bar Bushing Retainers
PLSUSPENSION 2 - 23
REMOVAL AND INSTALLATION (Continued)

(7) Place steering knuckle with wheel bearing
installed, in an arbor press with Receiver, Special
Tool MB-990799 supporting inner race of the wheel
bearing (Fig. 59). Place hub in wheel bearing making
sure it is square with bearing. Press hub into wheel
bearing until it is fully bottomed in the wheel bear-
ing.
(8) Install the steering knuckle, assembly on the
vehicle. Refer to Steering Knuckle in the Removal
And Installation section in this group of the service
manual for the required steering knuckle installation
procedure.
(9) Install the wheel and tire on the vehicle.
(10) Lower the vehicle.
(11) Set the front wheel Toe to the required speci-
fication. Refer to Wheel Alignment Check And
Adjustment Procedure in the Service Procedures Sec-
tion in this group of the service manual.
FRONT WHEEL MOUNTING STUDS
CAUTION: If a wheel attaching stud needs to be
replaced in the front hub/bearing, the stud CAN
NOT be hammered out of the hub flange. If the stud
is removed by hammering it out of the bearing
flange, damage to the hub bearing will occur lead-
ing to premature bearing failure.
The following procedure and special tools shown
MUSTbe used when replacing wheel attaching
studs.
The hub and bearing assembly does not require
removal from the steering knuckle to replace wheel
attaching studs in the hub and bearing assembly.
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, forthe required lifting procedure to be used for this
vehicle.
(2) Remove the front wheel and tire.
(3) Remove the 2 bolts (Fig. 60) attaching the disc
brake caliper to the steering knuckle .
(4) Remove the disc brake caliper from the steer-
ing knuckle. Caliper is removed by first lifting bot-
tom of caliper away from steering knuckle, and then
removing top of caliper out from under steering
knuckle (Fig. 61).
(5) Support the disc brake caliper using a wire
hook, (Fig. 62) not by the hydraulic flex hose.
(6) Remove the rotor from the front hub (Fig. 63).
(7) Install a lug nut on the wheel stud being
removed from the hub/bearing, so threads on stud
are even with end of lug nut (Fig. 64). Rotate hub so
stud requiring removal is aligned with notch cast
into front of steering knuckle. Install Remover, Spe-
cial Tool C-4150 on hub/bearing flange and wheel
stud (Fig. 64).
Fig. 59 Pressing Hub Into Wheel Bearing
Fig. 60 Caliper Attaching Bolts
Fig. 61 Brake Caliper Removal
2 - 28 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

Inspect the tension strut for signs of contact with
the ground or road debris which has bent or caused
other damage to the tension strut. If the tension
strut is bent or damaged the tension strut will
require replacement.Do not attempt to repair or
straighten a tension strut.
STABILIZER BAR AND BUSHINGS
Inspect the stabilizer bar for damage or bending.
Inspect for broken or distorted stabilizer bar bush-
ings, bushing retainers, and worn or damaged stabi-
lizer bar to strut attaching links. If stabiizer bar to
rear frame rail bushing replacement is required,
bushings can be removed from sway bar by opening
slit and peeling bushing off sway bar.
STABILIZER BAR ATTACHING LINKS
Inspect the bushings and sleeves in the stabilizer
bar attaching links for damage or deterioration.
Inspect the stabilizer bar attaching link to ensure it
is not bent or broken. If any of these conditions are
present when inspecting the attaching links, replace-
ment of the attaching link is required.
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT
Refer to Front And Rear Wheel Toe Setting Proce-
dures in the Wheel Alignment Check And Adjustment
section in this group of the service manual for the
required rear wheel Toe setting procedure.
REMOVAL AND INSTALLATION
STRUT ASSEMBLY
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) Remove hydraulic flex hose bracket, from
bracket on rear strut assembly (Fig. 6). If vehicle is
equipped with Anti-Lock brakes, the wheel speed
sensor cable routing clip is also attached to the strut
assembly bracket.
(4) Support rear knuckle, suspension and brake
components of vehicle before removing clevis bracket
to knuckle attaching bolts.Do not let weight of
rear knuckle and assembled components hang
unsupported when strut is removed.CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
removal. Remove nuts while holding bolts station-
ary in knuckle.
(5) Remove the 2 clevis bracket bolts (Fig. 7)
attaching strut assembly to rear knuckle.
(6) Lower vehicle. Access to rear upper strut
mount to strut tower attaching bolts, is through the
trunk of the vehicle.
Fig. 6 Hydraulic Flex Hose Bracket Attachment To
Strut
Fig. 7 Knuckle To Clevis Bracket Bolts
PLSUSPENSION 2 - 43
DIAGNOSIS AND TESTING (Continued)

strut assembly in the disassembly and assembly sec-
tion in this group of the service manual for the
required procedure to disassemble and assemble the
strut assembly for the removal of the coil spring.
STABILIZER BAR
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove both rear wheel and tire assemblies
from the vehicle.
(3) Remove rear stabilizer bar from the 2 stabilizer
bar to strut attaching links (Fig. 11).
(4) Rotate stabilizer bar down slightly to clear
attaching links.
(5) Remove the 2 stabilizer bar to rear frame rail
retainers (Fig. 12).(6) Remove stabilizer bar from vehicle.
STABILIZER BAR AND BUSHING INSPECTION
Inspect for broken or distorted retainers and bush-
ings. If bushing replacement is required, bushing can
be removed by opening slit in bushing and removing
bushing from around stabilizer bar. When bushings
are installed on stabilizer bar, bushings must be
installed with slit positioned on stabilizer bar so slit
will face rear of vehicle when stabilizer bar is
installed (Fig. 13).
INSTALL
(1) Install stabilizer bar and isolator bushings
back into the vehicle as an assembly. Position stabi-
lizer bar so it is centered in the vehicle and does not
contact other suspension components or vehicle body.
(2) Install the 2 stabilizer bar to frame rail retain-
ers into frame rail and loosely install both retainer
attaching bolts (Fig. 12).
(3) Position both stabilizer bar to strut assembly
attaching links on stabilizer bar. Install and securely
tighten the stabilizer bar attaching link to stabilizer
bar attaching nuts (Fig. 11).
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
Fig. 10 Identifying Coil Springs
Fig. 11 Sway Bar To Strut Attaching Link
Fig. 12 Sway Bar To Frame Rail Retainers
Fig. 13 Bushings Correctly Installed On Stabilizer
Bar
PLSUSPENSION 2 - 45
REMOVAL AND INSTALLATION (Continued)

sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 129 N´m (95 ft. lbs.).
(5) Lower the vehicle to the ground.
(6) With suspension supporting the full weight of
the vehicle, securely tighten the stabilizer bar
retainer to frame rail attaching bolts (Fig. 11).
KNUCKLE
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the rear wheel and tire.
(3) If vehicle is equipped with rear disc brakes,
remove the rear caliper from the adapter. Refer to
Rear Disk Brakes in Group 5 Brakes of this Service
manual for required caliper removal procedure. After
removing the caliper, store the caliper by hanging it
from frame of the vehicle (Fig. 14). Do not let weight
of rear caliper hang from flexible brake hose.
(4) If vehicle is equipped with rear disc brakes,
remove rotor from hub. If vehicle is equipped with
rear drum brakes, remove brake drum from hub.
(5) If vehicle is equipped with ABS brakes, remove
wheel speed sensor from rear disc brake adapter
(Fig. 15).
(6) Remove rear hub/bearing retaining nut (Fig.
16). Then remove the hub/bearing from the knuckle.(7) If vehicle is equipped with rear drum brakes
remove the 4 bolts (Fig. 17) attaching rear brake sup-
port plate to knuckle. Then remove brake support
plate, brake shoes and wheel cylinder as an assembly
from rear knuckle (Fig. 17).It is not necessary to
remove brake flex hose from wheel cylinder
when removing support plate.Brake support
plate when removed, must be supported in same
manner as caliper assembly.
(8) On vehicles equipped with rear disc brakes,
remove the 4 bolts attaching disc brake adapter to
rear knuckle (Fig. 18). Then remove the adapter,
rotor shield, park brake shoes and park brake cable
as an assembly from knuckle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
removal. Loosen and remove nuts while holding
bolts stationary in knuckle.
Fig. 14 Storing Rear Caliper
Fig. 15 Speed Sensor Head Attachment To Disc
Brake Adapter
Fig. 16 Hub/ Bearing Retaining Nut
2 - 46 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the rear wheel and tire assembly from
the side of the vehicle requiring lateral link removal.
(3) Remove the nut, bolt and washers attaching
the lateral links to the knuckle (Fig. 24).
(4) Remove nut, bolt, washer and Toe adjustment
cam, attaching lateral links requiring removal, from
rear crossmember (Fig. 25). Then remove lateral
links from vehicle.
INSTALL
Rear lateral links when being installed, must be
specifically positioned and orientated on the vehicle.The lateral link having same size bushing sleeves,
must be mounted to the crossmember and knuckle
toward front of vehicle. The lateral link with differ-
ent size bushing sleeves, must be mounted to the
crossmember and knuckle toward rear of vehicle. The
lateral link with small and large bushing sleeves,
must be installed with small bushing sleeve at
knuckle and large bushing sleeve at rear crossmem-
ber. This is required to accommodate the rear Toe
adjustment cam at rear crossmember.
The lateral link mounting bolts are different
lengths, and need to be installed in specific locations
and direction on vehicle.The lateral link mount-
ing bolt at knuckle MUST be installed, with
head of bolt facing front of vehicle. The lateral
Fig. 23 Rear Suspension Lateral Links
Fig. 24 Lateral Link Attachment To Knuckle
Fig. 25 Lateral Link Attachment To Crossmember
PLSUSPENSION 2 - 49
REMOVAL AND INSTALLATION (Continued)

vehicle is on the floor with the brakes applied. The
front hub and driveshaft are splined together and
retained by the hub nut.
(3) Raise vehicle on jack stands or centered on a
frame contact±type hoist. See Hoisting in the Lubri-
cation and Maintenance section for required lifting
procedure to be used for this vehicle.
(4) Remove front tire and wheel assembly from the
hub.
(5) Remove front disc brake caliper assembly to
steering knuckle bolts (Fig. 4).
(6) Remove disc brake caliper assembly from steer-
ing knuckle. Caliper is removed by first lifting bot-
tom of caliper away from steering knuckle, and then
removing top of caliper out from under steering
knuckle.
(7) Support brake caliper/adapter assembly using a
wire hook,not by the brake flex hose(Fig. 5).
(8) Remove braking disc from front hub.
(9) Remove nut attaching outer tie rod end to
steering knuckle.Nut is to be removed from tie
rod end using the following procedure: Hold tierod end stud with a 11/32 socket while loosen-
ing and removing nut.
(10) Remove the tie rod end stud from steering
knuckle arm using Special Tool MB-991113 (Fig. 6).
Fig. 2 Cotter Pin, Nut Lock and Spring Washer
Fig. 3 Loosening Front Hub Retaining Nut
Fig. 4 Front Disc Brake Caliper Assembly Bolts
Fig. 5 Supporting Brake Caliper
Fig. 6 Tie Rod End Removal From Steering Knuckle
PLDIFFERENTIAL AND DRIVELINE 3 - 3
REMOVAL AND INSTALLATION (Continued)

either through the park brake switch, the fluid level
sensor in the master cylinder reservoir, or the igni-
tion switch in the crank position.
The Brake Fluid Level sensor is located in the
brake fluid reservoir of the master cylinder assembly
(Fig. 18). The purpose of the sensor is to provide the
driver with an early warning that the brake fluid
level in the master cylinder reservoir has dropped to
below normal. This may indicate an abnormal loss of
brake fluid in the master cylinder fluid reservoir
resulting from a leak in the hydraulic system.
As the fluid drops below the minimum level, the
fluid level sensor closes the brake warning light cir-
cuit. This will turn on the red brake warning light.
At this time, master cylinder fluid reservoir shouldbe checked and filled to the full mark with DOT 3
brake fluid.If brake fluid level has dropped in
master cylinder fluid reservoir, the entire
brake hydraulic system should be checked for
evidence of a leak.
STOP LAMP SWITCH
The stop lamp switch controls operation of the
vehicles stop lamps. Also, if the vehicle is equipped
with speed control, the stop lamp switch will deacti-
vate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the
right and left tail, stop and turn signal lamp and
CHMSL lamp, by supplying battery current to these
lamps.
The stop lamp switch controls the lamp operation
by opening and closing the electrical circuit to the
stop lamps.
REAR WHEEL HUB/BEARING
CAUTION: If a vehicle is equipped with antilock
brakes the tone wheels for the rear wheel speed
sensors are pressed onto the hub. The tone wheels
used on this vehicle equipped with the Teves Mark
20 Antilock Brake System are different then those
used on past models of this vehicle equipped with
antilock brakes. Reduced braking performance will
result if this part is used on earlier model vehicles
and an accident could result. Do not use on
pre-1998 model year vehicles.
All vehicles are equipped with permanently lubri-
cated and sealed for life rear wheel bearings. There
is no periodic lubrication or maintenance recom-
mended for these units. However, if servicing of a
rear wheel bearing is required, refer to procedures in
the diagnosis and testing section and the removal
and installation section in this group of the service
manual for the inspection and replacement of the
rear wheel bearing.Fig. 17 Power Brake Booster Assembly
Fig. 18 Master Cylinder Fluid Level Sensor
5 - 8 BRAKESPL
DESCRIPTION AND OPERATION (Continued)