wheel alignment DODGE NEON 1999 Service User Guide

COMPETITION PACKAGE SUSPENSION
On vehicles that are equipped with the optional
competition package, special rear struts are used.
The rear struts used on a vehicle equipped with
the competition package are adjustable. The adjust-
able struts use a unique strut shaft which has an
adjustment rod through the center of it (Fig. 2). The
adjustment rod is used to adjust the compression
dampening of the strut. By increasing the compres-
sion dampening of the strut, the jounce reaction of
the strut is slowed down. This slowing down of the
jounce reaction of the strut, stiffens the suspension
thus improving the handling of the vehicle.
The compression dampening of the strut is
adjusted using the adjustment knob (Fig. 3) which is
supplied with the vehicle at the time of purchase.
STRUT
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around the
struts. The coil springs are contained between theupper mount of the strut assembly and a lower
spring seat on the body of the strut assembly.
The top of each strut assembly is bolted to the top
of the inner fender through a rubber isolated mount.
The bottom of the strut assembly attaches to the
rear knuckle using 2 thru-bolts and prevailing torque
nuts. Rear Caster and camber on this vehicle is a
fixed setting (net build) and is not required to be
adjusted as a normal procedure when performing an
alignment on this vehicle.
COIL SPRING
Rear coil springs are rated separately for each cor-
ner or side of the vehicle depending on optional
equipment and type of vehicle service. During service
procedures when both rear coil springs are removed,
mark the coil springs to ensure installation of the
springs in their original position.If coil springs
require replacement, be sure the springs need-
ing replacement, are replaced with springs
meeting the correct load rating for the vehicle
and its specific options.
STABILIZER BAR
The stabilizer bar interconnects both rear strut
assemblies and is attached to the rear frame rails of
the vehicle.
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 rear frame
rails of the vehicle is through 2 rubber-isolator bush-
ings and bushing retainers. The stabilizer bar to
strut assembly attachment is done utilizing a rubber
isolated stabilizer bar attaching link. All parts of the
stabilizer bar are serviceable, and the stabilizer bar
to frame rail isolator bushings are split for easy
removal and installation. The split in the stabilizer
bar to crossmember bushing must be positioned
toward the rear of the vehicle, when the stabilizer
bar is installed on the vehicle.
KNUCKLE
A forged rear knuckle bolts to each rear strut
assembly. The movement of the rear knuckle is con-
trolled laterally using two lateral arms attached to
the knuckle. The outboard ends of the two lateral
arms are mounted forward and rearward of the spin-
dle centerline, and inboard ends are mounted to the
rear crossmember. Fore and aft movement of the
knuckle is controlled by using a tension strut.
LATERAL LINKS AND TENSION STRUTS
The lateral arms and tension strut have rubber
isolator bushings at each end. The lateral arms are
attached to the rear crossmember and knuckle, using
Fig. 2 Adjustable Front Strut
Fig. 3 Adjustable Strut Adjustment Knob
PLSUSPENSION 2 - 41
DESCRIPTION AND OPERATION (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)

(7) Remove carpet (if required) from top of strut
tower. Then remove rubber dust shield (Fig. 8) from
top of strut tower, this will allow easier access to
upper strut mount attaching nuts.
(8) Loosen but do not remove the 4 upper strut
mount to strut tower attaching nuts (Fig. 9). Then
while supporting the strut assembly fully remove the
4 strut mount attaching nuts.
(9) Remove strut assembly from knuckle, by slid-
ing knuckle out of clevis bracket on strut assembly.
Then remove strut assembly from vehicle.
INSTALL
(1) Position strut assembly back into vehicle with
the 4 studs on strut mount assembly through holes
in strut tower of vehicle. Install the 4 strut mount to
body attaching nuts (Fig. 9) onto mount studs.
Torque the 4 strut mount to body attaching nuts to
34 N´m (300 in. lbs).(2) Install dust shield into hole on top of strut
tower (Fig. 8). Install carpeting back on top of rear
strut tower.
(3) Raise vehicle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
installation. Install and torque nuts while holding
bolts stationary in knuckle.
(4) Install knuckle assembly into clevis bracket on
strut assembly. Install the 2 clevis bracket to knuckle
assembly attaching bolts and nuts (Fig. 7). Torque
both clevis bracket to knuckle assembly attaching
nuts to 95 N´m (70 ft. lbs.).
(5) Install hydraulic flex hose bracket, on strut
assembly bracket (Fig. 6). Install and securely
tighten bolt attaching hose bracket to strut bracket.
If vehicle is equipped with Anti-Lock brakes, the
wheel speed sensor cable routing clip is also attached
to the strut assembly bracket.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat tightening sequence to full speci-
fied torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
(8) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
COIL SPRING
Coil springs are rated separately for each side of
vehicle depending on optional equipment and type of
service. During service procedures where both
springs are removed, mark springs (Chalk, Tape,
etc.) (Fig. 10) to ensure installation in original posi-
tion. If the coils springs require replacement.Be
sure that the springs needing replacement, are
replaced with springs meeting the correct load
and spring rate for the vehicle.
NOTE: During service procedures requiring
removal or installation of a coil spring with Spring
Compressor, Special Tool C-4838. It is required that
the first full top and bottom coil of the coil spring
be captured by the jaws of spring compressor (Fig.
10).
Replacement of the coil spring requires removal of
the strut assembly from the vehicle, and the disas-
sembly of the strut. Refer to strut assembly in the
removal and installation section in this group of the
service manual for the required removal and replace-
ment procedure for the strut assembly. Then refer to
Fig. 8 Dust Shield Removal From Strut Tower
Fig. 9 Strut Mount Attaching Nuts
2 - 44 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(4) Install tension strut bushing, tension strut
retainer and nut on tension strut (Fig. 21).When
installing tension strut retainers, the retainers
must be installed on tension strut, with cupped
side of retainer facing away from bushing and
knuckle (Fig. 21).
(5) Position a large adjustable wrench on flat of
tension strut to keep it from turning, (Fig. 22) and
then torque tension strut nut to 95 N´m (70 ft. lbs.).
(6) On vehicles equipped with rear drum brakes,
install rear brake support plate assembly onto the
knuckle (Fig. 17). Install the 4 bolts (Fig. 17) attach-
ing rear brake support plate to rear knuckle. Torque
attaching bolts to 68 N´m (50 ft. lbs.).
(7) On vehicles equipped with rear disc brakes,
install the disc brake adapter on knuckle (Fig. 18)
Install the 4 bolts attaching the disc brake adapter to
knuckle (Fig. 18). Torque attaching bolts to 68 N´m
(50 ft. lbs.).(8) If vehicle is equipped with ABS brakes, install
speed sensor head into rear brake support plate or
disc brake adapter (Fig. 15). Tighten wheel speed
sensor mounting bolt to a torque of 7 N´m (60 in.
lbs.).
CAUTION: The hub/bearing retaining nut must be
tightened to but must not exceed its required
torque specification. The proper torque specifica-
tion of the retaining nut is critical to the life of the
hub bearing.
(9) Install rear hub and bearing assembly on
knuckle. Install hub and bearing assembly retaining
nut (Fig. 16), and torque to 217 N´m (160 ft. lbs).
(10) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. If vehicle is
equipped with rear drum brakes, install the brake
drum on hub.
(11) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. Carefully install
rear brake caliper over braking disc and install on
adapter. Tighten the caliper assembly to adapter
mounting bolts to 22 N´m (192 in. lbs.). Refer to Rear
Disc Brakes in Group 5 Brakes in this service man-
ual for required caliper installation procedure.
(12) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(13) Lower vehicle.
(14) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(15) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
LATERAL LINKS
The rear suspension lateral links (Fig. 23) are only
serviced as complete assemblies. The isolator bush-
ings used in the lateral links are not serviced as sep-
arate components. The rear lateral link assemblies
are unique, having different size bushings to accom-
modate the rear Toe adjustment cams. The rearward
lateral links, must be installed with small bushing
sleeve at knuckle and large bushing sleeve at rear
crossmember. This is required to accommodate the
rear Toe adjustment cam.
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 21 Tension Strut Bushings Installed On Tension
Strut
Fig. 22 Torquing Tension Strut Nut
2 - 48 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

link mounting bolt at crossmember MUST be
installed, with head of bolt facing rear of vehi-
cle. The long attaching bolt must be used at
rear crossmember and short bolt used at
knuckle.
(1) Install washer on short lateral link attaching
bolt. Then install short lateral link attaching bolt,
into lateral link having the same size bushing
sleeves. Then install lateral link, bolt and washer
onto knuckle as an assembly, with head of bolt facing
to front of vehicle (Fig. 24).
(2) Install lateral link with small and large bush-
ing sleeve, on lateral link attaching bolt in rear
knuckle (Fig. 24).Small bushing sleeve must be
installed on bolt in rear knuckle with large
bushing sleeve at crossmember of vehicle.
(3) Install washer and nut onto lateral link attach-
ing bolt at rear knuckle (Fig. 24).Do not tighten
the lateral link to rear knuckle attaching bolt
at this time.
(4) Install Toe adjustment cam on long lateral link
attaching bolt. Install long lateral link attaching bolt
and adjustment cam, into lateral link toward rear of
vehicle, having the large bushing sleeve. Then pass
lateral link attaching bolt into rear crossmember
(Fig. 26).Head of long lateral link to crossmem-
ber attaching bolt must face to rear of vehicle
when installed.
(5) Position forward rear lateral link against rear
crossmember (Fig. 26). Then pass the lateral link
attaching bolt through front lateral link bushing
sleeve.
(6) Install washer and nut onto lateral link attach-
ing bolt at rear crossmember (Fig. 26).Do not
tighten the lateral link to rear crossmember
attaching bolt at this time.
(7) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(8) Lower vehicle to the ground.
(9) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(10) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY
DISASSEMBLY
The rear strut unit is not serviced and must be
replaced as an assembly if found to be defective. The
strut is available with 2 calibrations, be sure strut is
replaced with an assembly of the same calibration.
The components of the strut assembly listed below
are replaceable if found to be defective.
²Coil spring (Coil springs come in a standard rate
of 120 lb./in. be sure spring is replaced with a spring
of the same rate.)
²Dust shield
²Mount assembly
²Jounce Bumper
²Lower Spring Isolator
²Shaft Nut
(1) Remove strut assembly requiring service from
the vehicle. Refer to Strut Assembly Removal in Ser-
vicing Rear Struts, in this section of the service man-
ual.
(2) Position strut assembly in a vise (Fig. 27).
Using paint or equivalent, mark the strut unit, lower
spring isolator, spring and upper strut mount for
indexing of the parts at assembly.
(3) Position Spring Compressors, Special Tool
C-4838 on the strut assembly spring (Fig. 28). Com-
press coil spring until all load is removed from upper
strut mount assembly.
(4) Install Strut Rod Socket, Special Tool, L-4558A
or L-4558 on strut shaft nut (Fig. 29). Inserted a 10
mm socket through special tool and onto end of strut
shaft (Fig. 29) to keep strut shaft from turning.
Remove strut shaft nut from strut shaft.
(5) Remove washer (Fig. 30) between strut shaft
nut and upper strut mount and isolator.
(6) Remove upper strut mount assembly from strut
shaft and spring (Fig. 31).
Fig. 26 Lateral Link Attachment To Crossmember
2 - 50 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

the jounce and rebound travel of the front suspen-
sion.
On vehicles equipped with ABS brakes, the outer
C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.
The inner tripod joint of both driveshafts is splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle using
a snap ring located in the stub shaft of the tripod
joint. The outer C/V joint has a stub shaft that is
splined into the wheel hub and retained by a hub nut
using a nut lock and cotter pin.
NOTE: This vehicle does not use a rubber±lip bear-
ing seal as on previous front±wheel±drive cars to
prevent contamination of the front wheel bearing.
On these vehicles, the face of the outer C/V joint
fits deeply into the steering knuckle, using a close
outer C/V joint±to±steering knuckle fit. This design
deters direct water splash on bearing seal while
allowing any water that gets in, to run out the bot-
tom of the steering knuckle bearing bore. It is
important to thoroughly clean the outer C/V joint
and the wheel bearing area in the steering knuckle
before it is assembled after servicing.
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam-
age.
(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.
The right inner tripod joint seal boot is made of sili-
cone rubber; which will allow the weeping (sweating)
of the joint lubricant to pass through it while in oper-
ation.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions.
(1) Damaged outer C/V or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.
(2) Noise may also be caused by another compo-
nent of the vehicle coming in contact with the drive-
shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
(1) A torn seal boot on the inner or outer joint of
the driveshaft assembly.
(2) A loose or missing clamp on the inner or outer
joint of the driveshaft assembly.
(3) A damaged or worn driveshaft C/V joint.
SHUDDER OR VIBRATION DURING
ACCELERATION
(1) A worn or damaged driveshaft inner tripod
joint.
(2) A sticking tripod joint spider assembly (inner
tripod joint only).
(3) Improper wheel alignment. See Wheel Align-
ment in this group for alignment checking and set-
ting procedures and specifications.
VIBRATION AT HIGHWAY SPEEDS
(1) Foreign material (mud, etc.) packed on the
backside of the wheel(s).
(2) Out of balance front tires or wheels. See Group
22, Wheels And Tires for the required balancing pro-
cedure.
(3) Improper tire and/or wheel runout. See Group
22, Wheels And Tires for the required runout check-
ing procedure.
REMOVAL AND INSTALLATION
FRONT DRIVESHAFTS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the driveshaft
to prevent damage.
REMOVAL
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER±SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N´m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(1) Remove cotter pin, nut lock, and spring washer
(Fig. 2) from the end of the outer C/V joint stub axle.
(2) Loosen (but do not remove) stub axle±to±hub/
bearing retaining nut (Fig. 3). Loosen hub nut while
3 - 2 DIFFERENTIAL AND DRIVELINEPL
GENERAL INFORMATION (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)

A visual inspection for loose, disconnected, or mis-
routed wires should be done before attempting to
diagnose or service the ITT Teves Mark 20 antilock
brake system. A visual inspection will eliminate
unnecessary testing and diagnostics time. A thorough
visual inspection will include the following compo-
nents and areas of the vehicle.
(1) Inspect fuses in the power distribution center
(PDC) and the wiring junction block. Verify that all
fuses are fully inserted into the PDC and wring junc-
tion block. A label on the underside of the PDC cover
identifies the locations of the ABS fuses in the PDC.
(2) Inspect the 25-way electrical connector at the
CAB for damage, spread or backed-out wiring termi-
nals. Verify that the 25-way connector is fully
inserted in the socket on the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Poor mating of connector halves or terminals
not fully seated in the connector body.
(5) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(6) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
(7) Pin presence in the connector assembly
(8) Proper ground connections. Check all ground
connections for signs of corrosion, tight fasteners, or
other potential defects. Refer to wiring diagram man-
ual for ground locations.
(9) Problems with main power sources of the vehi-
cle. Inspect battery, generator, ignition circuits and
other related relays and fuses.
(10) If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the trouble code.
(11) Most failures of the ABS system will disable
ABS function for the entire ignition cycle even if the
fault clears before key-off. There are some failure
conditions, however, which will allow ABS operation
to resume during the ignition cycle in which a failure
occurred if the failure conditions are no longer
present. The following conditions may result in inter-
mittent illumination of the ABS Warning Lamp. All
other failures will cause the lamp to remain on until
the ignition switch is turned off. Circuits involving
these inputs to the CAB should be investigated if a
complaint of intermittent warning system operation
is encountered.
(12) Low system voltage. If Low System Voltage is
detected by the CAB, the CAB will turn on the ABS
Warning Lamp until normal system voltage is
achieved. Once normal voltage is seen at the CAB,
normal operation resumes.(13) High system voltage. If high system voltage is
detected by the CAB, the CAB will turn on the
Amber ABS Warning Lamp until normal system volt-
age is achieved. Once normal voltage is again
detected by the CAB, normal ABS operation resumes.
(14) Additionally, any condition which results in
interruption of electrical current to the CAB or mod-
ulator assembly may cause the ABS Warning Lamp
to turn on intermittently.
(15) The body controller can turn on the (yellow)
ABS warning lamp if CCD communication between
the body controller and the CAB is interupted.
TONEWHEEL INSPECTION
CAUTION: The tone wheels used on this vehicle
equipped with the Teves Mark 20 Antilock Brake
System are different then those used on past mod-
els 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.
Carefully inspect tonewheel at the suspected faulty
wheel speed sensor for missing, chipped or broken
teeth, this can cause erratic speed sensor signals.
Tonewheels should show no evidence of contact
with the wheel speed sensors. If contact was made,
determine cause and correct before replacing the
wheel speed sensor.
Excessive runout of the tonewheel can cause
erratic wheel speed sensor signals. Refer to Tone-
wheel Runout in the Specification Section in this sec-
tion of the service manual for the tonewheel runout
specification. Replace drive shaft assembly or rear
hub/bearing assembly if tonewheel runout exceeds
the specification.
Inspect tonewheels for looseness on their mounting
surfaces. Tonewheels are pressed onto their mounting
surfaces and should not rotate independently from
the mounting surface.
Check the wheel speed sensor head alignment to
the tone wheel. Also check the gap between the speed
sensor head and the tone wheel to ensure it is at
specification. Refer to Wheel Speed Sensor Clearance
in the Specification Section in this section of the ser-
vice manual.
PROPORTIONING VALVE
CAUTION: Proportioning valves should never be
disassembled.
If premature rear wheel skid occurs on a hard
brake application, it could be an indication that a
PLBRAKES 5 - 79
DIAGNOSIS AND TESTING (Continued)

CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS................... 1
CLUTCH DISC AND COVER APPLICATION.... 2
CLUTCH REPLACEMENT.................. 2
DESCRIPTION AND OPERATION
CLUTCH CABLE......................... 2
CLUTCH PEDAL POSITION SWITCH......... 2
DIAGNOSIS AND TESTING
CLASH±INTO±REVERSE COMPLAINTS....... 6
CLUTCH CHATTER COMPLAINTS........... 6
CLUTCH COVER AND DISC RUNOUT........ 6
CLUTCH DIAGNOSIS..................... 3
CLUTCH PEDAL POSITION SWITCH......... 2
DRIVE PLATE MISALIGNMENT............. 6
REMOVAL AND INSTALLATION
CLUTCH ASSEMBLY...................... 7CLUTCH CABLE......................... 6
CLUTCH PEDAL POSITION SWITCH......... 7
RELEASE BEARING AND FORK............. 9
CLEANING AND INSPECTION
CLEANING PRECAUTIONS................ 10
CLUTCH CONTAMINATION................ 10
ADJUSTMENTS
CLUTCH CABLE........................ 10
CLUTCH PEDAL POSITION SWITCH........ 11
SPECIFICATIONS
TORQUE.............................. 11
SPECIAL TOOLS
CLUTCH.............................. 11
GENERAL INFORMATION
CLUTCH COMPONENTS
NOTE: Neon vehicles produced at the Toluca
assembly plant, in Mexico, have conventional clutch
and flywheel assemblies. Vehicles produced at Bel-
videre assembly plant have modular clutch assem-
blies.
Before beginning clutch service, check the 11th
character of the V.I.N. to determine where it was
produced. The 11th character is ªDº for vehicles
produced at Belvidere, or ªTº for vehicles produced
at Toluca.
For a vehicle produced at Belvidere assembly,
refer to this manual for service information on the
modular clutch assembly. For a vehicle produced at
Toluca assembly, refer to the following information
to determine proper service procedures.
Service parts stock only a Conventional Clutch
Disc Assembly or a Modular Clutch Service Pack-
age to service Toluca built vehicles. The Modular
Clutch Service Package contains the following
parts:
²One modular clutch assembly
²One drive plate assembly
²One backing plate assembly
²Four drive plate to clutch bolts
²Eight drive plate to crankshaft boltsIf only the clutch disc requires replacement,
obtain the clutch disc. Replace the clutch disc
using the information in the Removal And Installa-
tion section of this manual.
If the clutch pressure plate or flywheel requires
replacement, obtain the Modular Clutch Service
Package. Refer to this manual for service informa-
tion on the modular clutch assembly.
The clutch assembly used in this vehicle consists of
a single, dry-type clutch disc and a diaphragm style
clutch cover.
The clutch disc has cushion springs riveted to the
disc hub assembly. The clutch disc facings are riveted
to the cushion springs. The facings are made from a
non-asbestos material.
The clutch cover pressure plate assembly is a dia-
phragm type unit with a one-piece diaphragm spring
with multiple release fingers. The pressure plate
release fingers are preset during manufacture and
are not adjustable.
A sleeve-type release bearing is used to engage and
disengage the clutch cover pressure plate. The bear-
ing is prelubed during manufacture and is a sealed
unit.
The release bearing is operated by a pivoting
release fork in the clutch housing. The fork pivots on
a ball stud within the housing. The release fork is
actuated by a self-adjusting clutch cable.
PLCLUTCH 6 - 1

CLUTCH PEDAL POSITION
SWITCH±MECHANICAL TEST
With the park brake set and the vehicleIN NEU-
TRAL,turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is
defective (shorted out) and must be replaced. If the
vehicle does not crank, proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.
With the park brake set and the vehicleIN GEAR,
turn the key to the start position and hold it there.
Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there
is no motion, the switch is working properly.
If motion is felt, check to see if the switch is mak-
ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch orthe self-adjusting cable (See ªClutch Will Not Disen-
gage Properlyº). If this condition is not met, then the
switch mounting tab on the brake bracket is bent,
and the brake bracket must be replaced.
If vehicle will not crank, even with clutch pedal
pressed to the floor, refer to ªService Diagnosis-
Clutch Pedal Position Switchº chart in this section.
CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road
test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSISÐCLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft sealCorrect leak and replace w/modular clutch
assembly
Too much grease applied to splines
of disc and input shaftApply lighter coating of grease to splines
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline componentFurther diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly)Replace w/modular clutch assembly
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for damage.
Correct as necessary.
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)