torque DODGE NEON 1999 Service User Guide

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)

(40 ft. lbs.) plus an additional 1/4 turn after specified
torque is met.
(3) Install hydraulic brake hose routing bracket
and attaching screw onto strut damper bracket. Ifvehicle is equipped with Anti-Lock brakes, hydraulic
hose routing bracket is combined with speed sensor
cable routing bracket (Fig. 12). Torque bracket
attaching bolts (Fig. 12) to 13 N´m (10 ft. lbs.).
(4) 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.).
STEERING KNUCKLE
REMOVE
(1) Remove cotter pin, nut lock, and spring washer
(Fig. 15).
CAUTION: Wheel bearing damage will result if
after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be
supported by the tires.
Fig. 12 Brake Hose And Speed Sensor Cable
Routing Brackets
Fig. 13 Strut To Steering Knuckle Attaching Bolts
Fig. 14 Strut To Shock Tower Mounting
Fig. 15 Cotter Pin, Nut Lock, And Spring Washer
PLSUSPENSION 2 - 17
REMOVAL AND INSTALLATION (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)

(3) Remove the 2 attaching links connecting the
stabilizer bar to the lower control arms (Fig. 34).
(4) Loosen but do not remove bolts attaching sta-
bilizer bar retainers to front suspension crossmember
(Fig. 35). Then rotate stabilizer bar and attaching
links away from lower control arms
CAUTION: Pulling steering knuckle out from vehi-
cle after releasing from ball joint can separate inner
C/V joint. See Driveshafts.
(5) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 36).Use caution when
separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
(6) Remove front lower control arm bushing to
crossmember attaching nut and bolt (Fig. 37).
Remove rear lower control arm to crossmember and
frame rail attaching bolt (Fig. 37). Then remove
lower control arm from crossmember.
INSTALL
(1) Position lower control arm into front crossmem-
ber. Then install rear lower control arm to crossmem-
ber and frame rail attaching bolt (Fig. 37).Do not
tighten rear attaching bolt at this time. Then
install front lower control arm to crossmember nut
and bolt (Fig. 37).
(2) Torque front lower control arm nut and bolt to
163 N´m (120 ft. lbs.), first and then torque rear
lower control arm attaching bolt to same torque spec-
ification.
(3) Install ball joint stud into steering knuckle.
Then install steering knuckle to ball joint stud
clamping bolt and nut (Fig. 33). Torque clamping bolt
to 95 N´m (70 ft. lbs.).
Fig. 34 Stabilizer Bar Link To Lower Control Arm
Attachment
Fig. 35 Stabilizer Bar To Crossmember Retainers
Fig. 36 Ball Joint Separation From Steering Knuckle
Fig. 37 Lower Control Arm Attaching Bolts
2 - 22 SUSPENSIONPL
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)

INSTALL
(1) If inspection determines replacement of stabi-
lizer bar to lower control arm attachment link bush-
ings is required, replace bushings before installing
stabilizer bar. Refer to (Fig. 42) for proper orientation
of attaching link bushing components.
(2) If stabilizer bar to front crossmember bushings
require replacement at time of inspection, install new
bushings before installing stabilizer bar. Bushings
are replaced by opening slit on bushings and peeling
them off stabilizer bar. Install new bushings on sta-
bilizer bar, by spreading bushing at slit and forcing
them on stabilizer bar.Bushings must be installed
on stabilizer bar with slit in bushing facing
front of vehicle when stabilizer bar is installed
(Fig. 43).
(3) Position stabilizer bar into front crossmember,
so cutouts in stabilizer bar bushings are aligned with
raised bead in crossmember. Install stabilizer bar
bushing retainers onto crossmember aligning raised
bead on retainer with cutouts in bushings (Fig. 44).Do not tighten stabilizer bar bushing retainers
at this time.
(4) Align stabilizer bar attaching link and bushing
assemblies with attaching link mounting holes in the
lower control arms (Fig. 45). Install stabilizer bar
attaching links into both lower control arms. Install
the attaching link to stabilizer bar bushing and
retaining nut. Torque the stabilizer bar attaching
link nut (Fig. 45) to 28 N´m (21 ft. lbs.).
(5) Lower vehicle so the suspension is supporting
the total weight of the vehicle.
(6) With lower control arms of the vehicle at curb
height, tighten stabilizer bar bushing to crossmember
retainer attaching bolts to 28 N´m (21 ft. lbs.) torque.
Fig. 42 Stabilizer Bar Attaching Link Assembly
Bushing Orientation
Fig. 43 Correct Stabilizer Bar To Crossmember
Bushing Installation
Fig. 44 Stabilizer Bar To Crossmember Bushing
Position
Fig. 45 Stabilizer Bar Link To Control Arm
Attachment
2 - 24 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

into the bore. Place steering knuckle in an arbor
press with Receiver, Special Tool C-4698-2 supporting
the steering knuckle (Fig. 56). Place Diver, Special
Tool 5052 (Fig. 56) on the outer race of the wheel
bearing. Press the wheel bearing into the steering
knuckle until it is fully bottomed in the bore of the
steering knuckle.
NOTE: Only the original or original equipment
replacement bolts are to be used to mount the bear-
ing retainer to the steering knuckle. If a bolt
requires replacement when installing the bearing
retainer plate refer to the Mopar Parts Catalog for
the correct replacement bolts.
(4)
Install the bearing retainer plate on the steering
knuckle (Fig. 57). Install the 3 bearing retainer mounting
bolts (Fig. 57). Tighten the bearing retainer plate mount-
ing bolts to a torque of 28 N´m (250 in. lbs.).
(5) Install removed wheel mounting stud into the
hub flange.(6) Place hub with wheel mounting stud installed
in an arbor press supported by Special Tool C-4698-1
(Fig. 58). Press wheel mounting stud into hub flange
until it is fully seated against the back side on the
hub flange (Fig. 58).
Fig. 58 Wheel Mounting Stud Installation In Hub
Fig. 54 Wheel Bearing Removal From Steering
Knuckle
Fig. 55 Removing Bearing Race From Hub
Fig. 56 Pressing Wheel Bearing Into Steering
Knuckle
Fig. 57 Wheel Bearing Retainer Plate
PLSUSPENSION 2 - 27
REMOVAL AND INSTALLATION (Continued)

(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)

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)