steering DODGE NEON 1999 Service Owner's Guide

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)

ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION PACKAGE
SUSPENSION
The front struts used on a vehicle equipped with
the competition package are adjustable. The adjust-
able front struts use a unique strut shaft with an
adjustment rod through the center of it (Fig. 89). The
adjustment rod is used to adjust the compression
dampening of the strut.
The compression dampening of the strut is adjusted
using the adjustment knob (Fig. 90) which is supplied
with the vehicle at the time of purchase. The adjust-
ment is done by inserting the flat on the end of the
adjustment rod into the grove on the adjustment knob
(Fig. 91). The compression dampening is increased by
rotating the adjustment knob in a counterclockwise
direction and decresed by rotating the adjustment knob
in a clockwise direction (Fig. 90).
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
McPHERSON STRUT:
To Shock Tower Attaching
Nuts....................34N´m(300 in. lbs.)
Clevis Bracket To
Steering Knuckle...........54N´m(40ft.lbs.)
+ 90É Turn
Strut Shaft Nut..............74N´m(55ft.lbs.)
STEERING KNUCKLE:
Ball Joint Stud To
Steering Knuckle Nut/Bolt. . . .95 N´m (70 ft. lbs.)
Disc Brake Caliper Bolts.......22N´m(16ft.lbs.)
STEERING GEAR:
To Crossmember
Attaching Bolts.............68N´m(50ft.lbs.)
Tie Rod End Adjusting
Sleeve Nut................75N´m(55ft.lbs.)
Tie Rod End To Steering
Knuckle Nut...............54N´m(40ft.lbs.)
FRONT SUSPENSION CROSSMEMBER:
To Body Attaching Bolts......163 N´m (120 ft. lbs.)
Lower Control Arm Pivot
Bolt....................163 N´m (120 ft. lbs.)
STABILIZER BAR:
Bushing Retainer To
Crossmember Bolts..........28N´m(21ft.lbs.)
To Control Arm Attaching
Link Nut..................28N´m(21ft.lbs.)
HUB AND BEARING:
Front Stub Axle To Hub
Bearing Nut.............183 N´m (135 ft. lbs.)
Wheel Mounting
LugNut...........109-150 N´m (80-110 ft. lbs.)
Fig. 89 Adjustable Front Strut
Fig. 90 Adjustable Strut Adjustment Knob
Fig. 91 Adjustment Knob Installation
2 - 36 SUSPENSIONPL

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)

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)

(11) Remove nut and bolt (Fig. 7) retaining ball
joint stud into steering knuckle.
NOTE: Use caution when separating ball joint stud
from steering knuckle, so ball joint seal does not
get damaged.
(12) Separate ball joint stud from steering knuckle
by prying down on lower control arm (Fig. 8).
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.
(13) Remove the hub and bearing to stub axle
retaining nut.
(14) Install Puller, Special Tool 6790 on hub and
bearing assembly (Fig. 9), using wheel lug nuts to
secure it in place.(15) Install a wheel lug nut on wheel stud to pro-
tect the threads on the stud. Install a flat blade pry
tool to keep hub from turning. Using Puller, force the
outer stub axle from the hub and bearing asssembly
(Fig. 10).
(16) Pull steering knuckle assembly out and away
from outer C/V joint of the driveshaft assembly (Fig.
11).
(17) Support outer end of the driveshaft assembly.
NOTE: Removal of the inner tripod joints is made
easier if you apply outward pressure on the joint as
you strike the punch with a hammer.
(18) Remove the inner tripod joints from the side
gears of the transaxle using a punch to dislodge the
inner tripod joint retaining ring from the transaxle
side gear. If removing the right side inner tripod
joint, position the punch against the inner tripod
joint (Fig. 12). Strike the punch sharply with a ham-
mer to dislodge the right inner joint from the side
gear. If removing the left side inner tripod joint, posi-
Fig. 7 Removing Steering Knuckle Clamp Bolt
Fig. 8 Separate Ball Joint Stud from Steering
Knuckle
Fig. 9 Puller Installed On Hub/Bearing Assembly
Fig. 10 Removing Stub Axle From Hub/Bearing
3 - 4 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

tion the punch in the groove of the inner tripod joint
(Fig. 13). Strike the punch sharply with a hammer to
dislodge the left inner tripod joint from the side gear.
(19) Hold inner tripod joint and interconnecting
shaft of driveshaft assembly (Fig. 14). Remove inner
tripod joint from transaxle by pulling it straight out
of transaxle side gear and transaxle oil seal.When
removing tripod joint, do not let spline or snap
ring drag across sealing lip of the transaxle to
tripod joint oil seal.
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.
INSTALLATION
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding driveshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into tran-
saxle side gear as far as possible by hand.
(3) Carefully align tripod joint with transaxle side
gears. Then grasp driveshaft interconnecting shaft
and push tripod joint into transaxle side gear until
fully seated.Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.
Fig. 11 Steering Knuckle Separation from Driveshaft
Fig. 12 Disengaging Right Inner Tripod Joint from
Transaxle
Fig. 13 Disengaging Left Inner Tripod Joint from
Transaxle
Fig. 14 Tripod Joint Removal from Transaxle
PLDIFFERENTIAL AND DRIVELINE 3 - 5
REMOVAL AND INSTALLATION (Continued)

(4) Clean all debris and moisture out of steering
knuckle (Fig. 15).
(5) Ensure that front of outer C/V joint, which fits
into steering knuckle (Fig. 16), is free of debris and
moisture before assembling into steering knuckle.
(6) Slide driveshaft back into front hub. Install
steering knuckle onto the ball joint stud (Fig. 17).
(7) Install aNEWsteering knuckle to ball joint
stud bolt and nut (Fig. 18). Tighten the nut and bolt
to 95 N´m (70 ft. lbs.).
(8) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle nut onto stud of tie
rod end. While holding stud of tie rod end stationary,
tighten tie rod end to steering knuckle nut. Then,
using a crowfoot and 11/32 socket, tighten tie rod end
nut to 61 N´m (45 ft. lbs.).
(9) Install braking disc back on hub and bearing
assembly.
(10) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding top ofcaliper under top abutment on steering knuckle.
Then installing bottom of caliper against bottom
abutment of steering knuckle.
(11) Install caliper assembly to steering knuckle
bolts (Fig. 19). Tighten to 31 N´m (23 ft. lbs.).
(12) Clean all foreign matter from threads of outer
C/V joint stub axle. Install washer and hub nut onto
the threads of the stub axle and tighten nut.
(13) Install spring washer, nut lock, and cotter pin
on outer C/V joint stub axle (Fig. 20).
(14) With vehicle brakes applied to keep axle shaft
from turning, tighten hub nut to 203 N´m (150 ft.
lbs.).
(15) Install front wheel and tire assembly. Install
front wheel lug nuts and tighten to 135 N´m (100 ft.
lbs.).
(16) Check for correct fluid level in transaxle
assembly. Refer to Group 21 Transaxle, for the cor-
Fig. 15 Steering Knuckle to C/V Joint Sealing Area
Fig. 16 Outer C/V Joint Inspection
Fig. 17 Driveshaft Installation Into Hub And Steering
Knuckle
Fig. 18 Tighten Steering Knuckle Clamp Bolt
3 - 6 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

BASE BRAKE SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES.............. 6
FRONT DISC BRAKES..................... 2
MASTER CYLINDER...................... 6
PARKING BRAKES........................ 4
PROPORTIONING VALVES................. 5
REAR DISC BRAKES...................... 4
REAR DRUM BRAKES..................... 4
REAR WHEEL HUB/BEARING............... 8
RED BRAKE WARNING LAMP............... 7
STOP LAMP SWITCH...................... 8
VACUUM BOOSTER...................... 6
DIAGNOSIS AND TESTING
BRAKE FLUID CONTAMINATION............ 19
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE.... 9
BRAKE SYSTEM DIAGNOSIS CHARTS....... 10
DRUM BRAKE AUTOMATIC ADJUSTER....... 14
PROPORTIONING VALVES................ 16
RED BRAKE WARNING LAMP TEST......... 19
ROTOR THICKNESS AND RUNOUT.......... 14
STOP LAMP SWITCH TEST PROCEDURE..... 19
SERVICE PROCEDURES
BRAKE BLEEDING....................... 20
BRAKE DRUM MACHINING................ 23
BRAKE FLUID LEVEL CHECK.............. 19
BRAKE ROTOR MACHINING............... 22
BRAKE TUBE REPAIR.................... 25
MASTER CYLINDER BLEEDING............ 21
PARK BRAKE LEVER AUTO ADJUSTER
MECHANISM.......................... 23
REMOVAL AND INSTALLATION
CHASSIS TUBES AND HOSES.............. 47
FRONT DISC BRAKE CALIPER............. 26
FRONT DISC BRAKE SHOES.............. 28
MASTER CYLINDER..................... 41
PARK BRAKE CABLES.................... 50
PARK BRAKE LEVER ASSEMBLY........... 48PARK BRAKE LEVER OUTPUT CABLE....... 49
PARK BRAKE SHOES WITH REAR DISC
BRAKES............................. 55
PROPORTIONING VALVE (BASE BRAKES).... 47
REAR BRAKE DRUM..................... 34
REAR BRAKE SHOE SUPPORT PLATE....... 37
REAR BRAKE SHOES.................... 35
REAR BRAKE WHEEL CYLINDER........... 38
REAR DISC BRAKE CALIPER.............. 30
REAR DISC BRAKE SHOES................ 32
REAR HUB/BEARING..................... 39
STOP LAMP SWITCH..................... 57
VACUUM BOOSTER..................... 44
WHEEL AND TIRE ASSEMBLY.............. 26
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID LEVEL SWITCH............. 58
BRAKE FLUID RESERVOIR................ 57
FRONT AND REAR DISC BRAKE CALIPER.... 58
WHEEL CYLINDER (REAR DRUM BRAKE).... 63
CLEANING AND INSPECTION
CHASSIS TUBES AND HOSES.............. 65
FRONT DISC BRAKES.................... 63
REAR DISC BRAKES..................... 64
REAR DRUM BRAKE WHEEL CYLINDER...... 65
REAR DRUM BRAKES.................... 64
REAR WHEEL HUB AND BEARING ASSEMBLY . 65
ADJUSTMENTS
PARK BRAKE ADJUSTMENT............... 66
REAR DRUM BRAKE SHOE ADJUSTMENT.... 65
STOP LAMP SWITCH..................... 65
SPECIFICATIONS
BRAKE ACTUATION SYSTEM.............. 67
BRAKE FASTENER TORQUE SPECIFICATIONS . 67
BRAKE FLUID.......................... 67
SPECIAL TOOLS
BASE BRAKE SYSTEM................... 68
DESCRIPTION AND OPERATION
FRONT DISC BRAKES
The front disc brakes (Fig. 1) and (Fig. 2) consists
of the following components:
²The driving hub
²Braking disc (rotor)
²Caliper assembly - single piston, floating type
²Brake shoes and linings
The double pin calipers are mounted directly to the
steering knuckles and use no adapter. The caliper ismounted to the steering knuckle using bushings,
sleeves and 2 guide pin bolts which thread directly
into bosses on the steering knuckle (Fig. 2) and (Fig.
3).
Two machined abutments on the steering knuckle
position the caliper. The guide pin bolts, sleeves and
bushings control the side to side movement of the
caliper. The piston seal is designed to pull the piston
back into the bore of the caliper when the brake
pedal is released. This maintains the proper brake
shoe to rotor clearance (Fig. 4).
5 - 2 BRAKESPL

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

DRUM BRAKE AUTOMATIC ADJUSTER
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the rear adjustment slot in each brake
support plate to provide access to the adjuster star
wheel. Then, to eliminate the possibility of maximum
adjustment, back the star wheel off approximately 10
notches. It will be necessary to hold the adjuster
lever away from the star wheel to permit this adjust-
ment.
Apply the brake pedal. This application of force
will cause the brake shoes to leave the anchor. Upon
application of the brake pedal, the lever should move
downward, turning the star wheel. Thus, a definite
rotation of the adjuster star wheel can be observed if
the automatic adjuster is working properly. If one or
more adjusters do not function properly, the respec-
tive drum must be removed for adjuster servicing.
ROTOR THICKNESS AND RUNOUT
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Before refinishing or refacing a rotor, the disc
should be checked and inspected for the following
conditions:
Braking surface scoring, rust, impregnation of lin-
ing material and worn ridges.
Excessive lateral runout or wobble.
Thickness variation (Parallelism).
Dishing or distortion (Flatness).
If a vehicle has not been driven for a period of
time, the rotor surface will rust in the area not cov-
ered by the brake lining and cause noise and chatter
when the brakes are applied.
Excessive wear and scoring of the rotor can cause
temporary improper lining contact if ridges are not
removed before installation of new brake pad assem-
blies.
Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock back. This will
increase guide pin sleeve wear due to tendency of cal-
iper to follow rotor wobble.
Thickness variation in a rotor can also result in
pedal pulsation, chatter and surge due to variation in
brake output. This can also be caused by excessive
runout in rotor or hub.
Dishing or distortion can be caused by extreme
heat and abuse of the brakes.
ROTOR RUNOUT AND THICKNESS VARIATION
On vehicle rotor runout is the combination of the
individual runout of the hub face and the runout ofthe rotor. (The hub and rotor runouts are separable).
To measure runout on the vehicle, remove the wheel
and reinstall the lug nuts tightening the rotor to the
hub. Mount Dial Indicator, Special Tool C-3339 with
Mounting Adaptor, Special Tool SP- 1910 on steering
arm. Dial indicator plunger should contact braking
surface of rotor approximately one inch from edge of
rotor (Fig. 19). Check lateral runout (both sides of
rotor) runout should not exceed 0.13 mm (0.005
inch).
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing rotor
from hub, make a chalk mark across both the rotor
and one wheel stud on the high side of runout so
you'll know exactly how the rotor and hub was orig-
inally mounted (Fig. 20). Remove rotor from hub.
Install Dial Indicator, Special Tool C-3339 and
Mounting Adaptor, Special Tool SP-1910 on steering
knuckle. Position stem so it contacts hub face near
Fig. 19 Checking Rotor For Runout
Fig. 20 Marking Rotor and Wheel Stud
5 - 14 BRAKESPL
DIAGNOSIS AND TESTING (Continued)