service DODGE NEON 1999 Service User Guide

(5) Rotate lateral link adjustment cams (Fig. 7)
until the preferred rear Toe specification is obtained.
See Alignment Specifications in this group of the ser-
vice manual for preferred specification.
(6) While holding Toe adjustment cams from turn-
ing, tighten left and right lateral links to rear cross-
member attaching bolt nuts. This will securely hold
adjustment cams in position. Then while holding lat-
eral link attaching bolt and adjustment cam from
turning, torque nut of lateral link attaching bolt to
95 N´m (70 ft. lbs.) (Fig. 8).CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(7) Loosen inner to outer tie rod end jam nuts (Fig.
9). Grasp inner tie rods at serrations and rotate tie
rods (Fig. 9) to set the front wheel Toe to the pre-
ferred specification. See Alignment Specifications in
this group of the service manual for preferred speci-
fication.
(8) Tighten tie rod locknuts to 54 N´m (40 ft. lbs.)
torque.
(9) Adjust steering gear to tie rod boots at tie rod.
(10) Remove steering wheel clamp.
Fig. 7 Rear Wheel Toe Adjustment Cams
Fig. 8 Torquing Rear Lateral Link Attaching Bolts
Fig. 9 Front Wheel Toe Adjustment
2 - 8 SUSPENSIONPL
SERVICE PROCEDURES (Continued)

(Fig. 6). The rear of the lower control arm is mounted
to both the front crossmember and the frame rail of
the vehicle using a thru-bolt. The thru-bolt goes
through both the crossmember and rear lower control
arm bushing, threading directly into the frame rail of
the vehicle. The lower control arms are inter-con-
nected through a linked rubber isolated stabilizer
bar.
STABILIZER BAR
The stabilizer bar (Fig. 7) interconnects both front
lower control arms of the vehicle and is attached to
the front suspension cradle.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle to stabilize body roll.
Attachment of the stabilizer bar to the front sus-
pension cradle is through 2 rubber-isolator bushings
and bushing retainers (Fig. 7). The stabilizer bar to
lower control arm attachment is done utilizing a rub-
ber isolated stabilizer bar attaching link (Fig. 7). All
parts of the stabilizer bar are serviceable, and the
stabilizer bar to crossmember bushings are split for
easy removal and installation. The split in the stabi-
lizer bar to crossmember bushing must be positioned
toward the front of the vehicle, when the stabilizer
bar is installed on the vehicle.
FRONT WHEEL HUB BEARING
The front hub bearing used on this vehicle is a
Unit 1 type cartridge bearing.
The wheel bearing is serviced separately from the
front steering knuckle and front hub. The hub bear-
ing is held in the steering knuckle by an interference
press fit and a retaining plate which is bolted to the
front of the steering knuckle. Installation of the front
hub into the wheel bearing must be done after the
wheel bearing and retaining plate is installed in the
steering knuckle.The unit 1 wheel bearing is serviced only as a com-
plete assembly less the wheel hub. If the front wheel
bearing requires replacement, the hub must be
removed from the original wheel bearing and trans-
ferred to the replacement bearing.
COIL SPRING
Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service. During service procedures
when both springs are removed, mark springs to
ensure installation in original position. Each coil
spring comes with a plastic sleeve on the second coil
of the spring. This plastic sleeve is a noise insulator
for the coil spring.
NOTE: If coil springs require replacement, be sure
that the springs needing replacement, are replaced
with springs meeting the correct load rating for the
vehicle and its specific options.
BALL JOINT
The ball joint (Fig. 8) is pressed into the lower con-
trol arm and has a non-tapered stud with a notch for
steering knuckle clamp bolt clearance. The ball joint
stud is clamped and locked into the steering knuckle
leg using a pinch bolt. The ball joint used on this
vehicle is replaceable and if found defective can be
serviced as a separate component of the lower control
arm assembly.
WHEEL MOUNTING STUDS
If wheel attaching studs need to be replaced in the
hub and bearing assembly the studsCAN NOTbe
hammered out of the hub flange. If a stud is removed
by hammering it out of the bearing flange, damage to
the hub and bearing assembly will occur leading to
premature bearing failure.
Fig. 6 Lower Control Arm Assembly
Fig. 7 Stabilizer Bar And Components
2 - 14 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

Use the procedure and special tools shown in the
service procedures section for the wheel mounting
studs when replacing the wheel attaching studs.
The hub and bearing assembly does not require
removal from the steering knuckle or the rear
knuckle to replace the wheel attaching studs in the
hub and bearing assembly.
DIAGNOSIS AND TESTING
MCPHERSON STRUT ASSEMBLY
(1) Inspect for damaged or broken coil springs
(Fig. 9).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 9).(3) Lift dust boot (Fig. 10) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage
between the strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly. Also inspect jounce bumpers for signs of
damage or deterioration.
STEERING KNUCKLE
The front suspension steering knuckle is not a
repairable component of the front suspension.IT
MUST BE REPLACED IF FOUND TO BE DAM-
AGED IN ANY WAY.If it is determined that the
steering knuckle is bent when servicing the vehicle,
no attempt is to be made to straighten the steering
knuckle.
On this vehicle the steering knuckle must be
removed from the vehicle when servicing the front
hub bearing.
LOWER CONTROL ARM
If damaged, the lower control arm casting is ser-
viced only as a complete component. Inspect lower
control arm for signs of damage from contact with
the ground or road debris. If lower control arm shows
any sign of damage, inspect lower control arm for
distortion.Do not attempt to repair or straighten
a broken or bent lower control arm.
The serviceable components of the lower control
arm are: the ball joint assembly, ball joint assembly
grease seal and control arm bushings. Inspect both
control arm bushings for severe deterioration, and
replace if required. Inspect ball joint per inspection
procedure in this section of the service manual and
replace if required. Service procedures to replace
these components are detailed in the specific compo-
Fig. 8 Ball Joint Assembly
Fig. 9 McPherson Strut Assembly Inspection
Fig. 10 Strut Assembly Leakage Inspection
PLSUSPENSION 2 - 15
DESCRIPTION AND OPERATION (Continued)

nent removal and installation sections in this group
of the service manual.
BALL JOINT ASSEMBLY
With the weight of the vehicle resting on the road
wheels. Grasp the grease fitting as shown in (Fig. 11)
and with no mechanical assistance or added force
attempt to move the grease fitting.
If the ball joint is worn the grease fitting will move
easily. If movement is noted, replacement of the ball
joint is recommended.
STABILIZER BAR
Inspect for broken or distorted sway bar bushings,
bushing retainers, and worn or damaged sway bar to
strut attaching links. If sway bar to front suspension
cradle bushing replacement is required, bushing can
be removed from sway bar by opening slit and peel-
ing bushing off sway bar.
HUB/BEARING
The hub bearing is designed for the life of the vehi-
cle and requires no type of periodic maintenance. The
following procedure may be used for diagnosing the
condition of the hub bearing.
With the wheel, disc brake caliper, and brake rotor
removed, rotate the wheel hub. Any roughness or
resistance to rotation may indicate dirt intrusion or a
failed hub bearing. If the hub bearing exhibits any of
these conditions during diagnosis, the hub bearing
will require replacement, the bearing is not service-
able.
Damaged bearing seals and the resulting excessive
grease loss may also require bearing replacement.
Moderate grease weapage from the hub bearing is
considered normal and should not require replace-
ment of the hub bearing.
REMOVAL AND INSTALLATION
MCPHERSON STRUT
REMOVE
WARNING: DO NOT REMOVE STRUT ROD NUT
WHILE STRUT ASSEMBLY IS INSTALLED IN VEHI-
CLE, OR BEFORE STRUT ASSEMBLY SPRING IS
COMPRESSED.
(1) Loosen wheel nuts.
(2) 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.
(3) Remove wheel and tire assembly from location
on front of vehicle requiring strut removal.
(4) If both strut assemblies are removed, mark the
strut assemblies right or left according to which side
of the vehicle they were removed from.
(5) Remove hydraulic brake hose routing bracket
and attaching screw from strut damper bracket. If
vehicle is equipped with Anti-Lock brakes, hydraulic
hose routing bracket is combined with speed sensor
cable routing bracket (Fig. 12).
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 bolts (Fig. 13) attaching the strut
to the steering knuckle.
(7) Remove the 3 nuts attaching the upper mount
of the strut (Fig. 14) to the strut tower of the vehicle
.
INSTALL
(1) Install strut assembly into strut tower, aligning
the 3 studs on the upper strut mount into the holes
in shock tower. Install the 3 upper strut mount
retaining nut and washer assemblies (Fig. 14).
Torque the 3 nuts to 31 N´m (23 ft. lbs.).
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.
(2) Align strut assembly with steering knuckle.
Position arm of steering knuckle into strut assembly,
aligning the strut assembly to steering knuckle
mounting holes. Install the 2 strut assembly to steer-
ing knuckle attaching bolts (Fig. 13). Attaching bolts
should be installed with the nuts facing the front of
the vehicle. Torque both attaching bolts to 53 N´m
Fig. 11 Checking Ball Joint Wear
2 - 16 SUSPENSIONPL
DIAGNOSIS AND TESTING (Continued)

CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(14) Remove the 2 steering knuckle to strut
damper clevis bracket attaching bolts (Fig. 26).
(15)The cartridge type front wheel bearing
used on this vehicle is not transferable to the
replacement steering knuckle. If the replace-
ment steering knuckle does not come with a
hub and bearing assembly, a new bearing must
be installed in the steering knuckle. Installa-
tion of the new wheel bearing must be done
before installing steering knuckle on vehicle.
Refer to Hub and Bearing Service in this section of
the service manual for proper wheel bearing removal
and installation procedure.
INSTALL
(1) Install a new cartridge hub and bearing assem-
bly into the steering knuckle. Refer to Hub And Bear-
ing Service in this section of the service manual for
proper wheel bearing removal and installation proce-
dure.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.
(2) Install steering knuckle back in clevis bracket
of strut damper assembly (Fig. 26). Install the strut
damper to steering knuckle attaching bolts.Note:
The steering knuckle to strut assembly attach-
ing bolts are serrated and must not be turned
in steering knuckle during installation.Torqueattaching nuts to 54 N´m (40 ft. lbs.) plus an addi-
tional 1/4 turn after specified torque is met.
(3) Slide drive shaft back into front hub and bear-
ing assembly. Then install steering knuckle onto the
ball joint stud (Fig. 25).
(4) Install aNEWsteering knuckle to ball joint
stud, clamp bolt and nut (Fig. 23). Torque the clamp
bolt to 100 N´m (75 ft. lbs.).
(5) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 21). Then using a crow-
foot and 11/32 socket (Fig. 27), torque tie rod end
attaching nut to 55 N´m (40 ft. lbs.).
(6) Install the rotor on the hub/bearing (Fig. 20).
(7) Install the disc brake caliper on the steering
knuckle. Caliper is installed by first sliding top of
caliper under top abutment on steering knuckle.
Then installing bottom of caliper against bottom
abutment of steering knuckle (Fig. 28).
Fig. 28 Brake Caliper Installation
Fig. 26 Remove Steering Knuckle To Strut Attaching
Bolts
Fig. 27 Torquing Tie Rod End Attaching Nut
2 - 20 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)

WHEEL BEARING
REMOVE
(1) Remove steering knuckle, hub and wheel bear-
ing as an assembly from the vehicle. Refer to Steer-
ing Knuckle in the Removal And Installation section
in this group of the service manual for the required
steering knuckle removal procedure.
The removal and installation of the wheel
bearing from the steering knuckle is ONLY to
be done with the steering knuckle removed
from the vehicle. Removal of the wheel bearing
from the steering knuckle MUST be done using
an arbor press and the following procedure.
(2) Using Remover, Special Tool 4150A, (Fig. 46)
press one wheel mounting stud out of hub flange.
(3) Rotate hub to align removed wheel mounting
stud with notch in bearing retainer plate (Fig. 47).
Remove wheel mounting stud from hub.(4) Rotate hub so hole in hub that wheel mounting
stud was removed from, is facing away from brake
caliper lower rail on steering knuckle (Fig. 48).
Install one half of the Bearing Splitter, Special Tool
1130, between the hub and the bearing retainer plate
(Fig. 48).The threaded hole in this half of the
bearing splitter (Fig. 48) is to be aligned with
the caliper rail on the steering knuckle (Fig.
48).
(5) Install remaining pieces of Bearing Splitter,
Special Tool 1130, on steering knuckle (Fig. 49).
Hand tighten nuts (Fig. 49) to hold bearing splitter
in place on steering knuckle.
Fig. 46 Pressing Out Wheel Mounting Stud
Fig. 47 Stud Removal From Hub
Fig. 48 Bearing Splitter Half Installed On Steering
Knuckle
Fig. 49 Bearing Splitter Installed
PLSUSPENSION 2 - 25
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)

(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)