warning DODGE NEON 2000 Service User Guide

removed from, and which strut the coil spring was
removed from.
(2) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Set the lower hooks (Fig. 24), then set
the upper hooks (Fig. 25). Position the strut clevis
bracket straight outward away from the compressor.
Place a clamp on the lower end of the coil spring, so
the strut is held in place once the strut shaft nut is
removed (Fig. 24).
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.
(3) Compress the coil spring until all coil spring
tension is removed from the upper mount.
(4) Once the spring is sufficiently compressed,
install Strut Nut Socket, Special Tool 6864, on the
strut shaft retaining nut (Fig. 26). Next, install a
socket on the hex on the end of the strut shaft. Whileholding the strut shaft from turning, remove the nut
from the strut shaft.
Fig. 24 Strut Assembly In Compressor (Lower)
1 ± LOWER HOOKS
2 ± CLAMP
3 ± STRUT ASSEMBLY
4 ± CLEVIS BRACKET
5 ± SPRING COMPRESSOR
Fig. 25 Strut Assembly In Compressor (Upper)
1 ± NOTCH IN UPPER SEAT
2 ± UPPER MOUNT
3 ± UPPER HOOKS
4 ± CLEVIS BRACKET
Fig. 26 Shaft Nut Removal/Installation
1 ± SPRING COMPRESSOR
2 ± SPECIAL TOOL 6864
3 ± UPPER MOUNT
PLSUSPENSION 2 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

REAR SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
REAR SUSPENSION SYSTEM.............35
STRUT ASSEMBLY (REAR)................37
KNUCKLE (REAR).......................37
HUB AND BEARING (REAR)...............37
LATERAL ARMS........................37
TENSION STRUT.......................38
STABILIZER BAR (REAR).................38
DIAGNOSIS AND TESTING
STRUT ASSEMBLY (REAR)................38
KNUCKLE (REAR).......................39
HUB AND BEARING (REAR)...............39
LATERAL ARMS........................39
TENSION STRUT.......................39
STABILIZER BAR (REAR).................39REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........40
STRUT ASSEMBLY (REAR).................40
KNUCKLE (REAR)........................42
HUB AND BEARING (REAR)................44
LATERAL ARMS..........................45
TENSION STRUT.........................46
STABILIZER BAR (REAR)...................47
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (REAR).................47
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS........................50
SPECIAL TOOLS
REAR SUSPENSION......................50
DESCRIPTION AND OPERATION
REAR SUSPENSION SYSTEM
The rear suspension system used on this vehicle is
a fully independent type rear suspension system (Fig.
1). This means that each side of the rear suspension
acts independently from the other.
The rear suspension is supported by a strut assem-
bly. The strut assembly also controls ride quality.When the vehicle strikes a bump, the force is trans-
ferred through the hub, bearing, and knuckle, into
the strut assembly to absorb the force and dampen it.
Lateral movement of the rear knuckle is controlled
by lateral arms going from the front and rear of the
knuckle to the rear crossmember. Fore and aft move-
ment of the knuckle is controlled by a tension strut.
PLSUSPENSION 2 - 35

REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT WHILE STRUT ASSEMBLY IS INSTALLED IN
VEHICLE, OR BEFORE THE COIL SPRING IS COM-
PRESSED WITH A COMPRESSION TOOL. THE
SPRING IS HELD UNDER HIGH PRESSURE.
CAUTION: Only frame contact or wheel lift hoisting
equipment can be used on vehicles having a fully
independent rear suspension. Vehicles with inde-
pendent rear suspension can not be hoisted using
equipment designed to lift a vehicle by the rear
axle. If this type of hoisting equipment is used dam-
age to rear suspension components will occur.
NOTE: If a rear suspension component becomes
bent, damaged or fails, no attempt should be made
to straighten or repair it. Always replace it with a
new component.
STRUT ASSEMBLY (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) If the vehicle is equipped with rear drum
brakes, remove the screw securing the brake hose
bracket to the rear of the strut assembly (Fig. 5).
(4) If the vehicle is equipped with the antilock
brake system (ABS), remove the screw securing the
ABS wheel speed sensor bracket to the rear of the
strut assembly (Fig. 6).
(5) Remove the nut from the end of the rear stabi-
lizer bar link bolt (Fig. 5). Pull the bolt out through
the top of the link and remove the link.
(6) If the vehicle is equipped with rear disc brakes
(Fig. 7), perform the following:
²Remove the two guide pin bolts securing the
front disc brake caliper to the steering knuckle.
²Remove the disc brake caliper from the knuckle
and brake rotor.²Hang the caliper out of the way using a wire
hanger or cord. Do not support the caliper by letting
it hang by the hydraulic hose.
Fig. 5 Rear of Strut Assembly
1 ± BRAKE HOSE BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
Fig. 6 Rear of Strut Assembly with ABS
1 ± ABS WHEEL SPEED SENSOR BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
2 - 40 SUSPENSIONPL

²Place the link center sleeve and bushings
between the eye in the end of the stabilizer bar and
the link mounting bracket on the strut.
²Start the stabilizer bar link bolt with bushing
from the top, down through the stabilizer bar, inner
link bushings and sleeve, and strut link mounting
bracket.
²Install a lower bushing, then the nut. Do not
tighten the nut at this time.
(8) If the vehicle is equipped with the antilock
brake system (ABS), install the screw securing the
ABS wheel speed sensor bracket to the rear of the
strut assembly (Fig. 6). Tighten the mounting screw
to a torque of 13 N´m (120 in. lbs.).
(9) If the vehicle is equipped with rear drum
brakes, install the screw securing the brake hose
bracket to the rear of the strut assembly (Fig. 5).
Tighten the screw to a torque of 31 N´m (275 in. lbs.).
(10) Install the tire and wheel assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Repeat the tightening sequence, this time, to
full specified torque of 135 N´m (100 ft. lbs.).
(11) Lower the vehicle to ground level.
(12) Tighten the stabilizer bar link nut to a torque
of 23 N´m (200 in. lbs.).
(13) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
KNUCKLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) If the vehicle is equipped with rear drum
brakes, remove the screw securing the brake hose
bracket to the rear of the strut assembly (Fig. 5).
(4) If the vehicle is equipped with the antilock
brake system (ABS), remove the screw securing the
ABS wheel speed sensor bracket to the rear of the
strut assembly (Fig. 6).
(5) If the vehicle is equipped with rear drum
brakes, remove any retainer clips from the wheel
mounting studs, then pull the brake drum off the
hub and bearing.
(6) If the vehicle is equipped with rear disc brakes
(Fig. 7), perform the following:²Remove the two guide pin bolts securing the
front disc brake caliper to the steering knuckle.
²Remove the disc brake caliper from the knuckle
and brake rotor.
²Hang the caliper out of the way using a wire
hanger or cord. Do not support the caliper by letting
it hang by the hydraulic hose.
²Remove any retainer clips from the wheel
mounting studs, then pull the brake rotor off the hub
and bearing.
(7) Remove the dust cap from the hub and bearing
assembly (Fig. 7).
(8) Remove the retaining nut, then the hub and
bearing from the knuckle's spindle (Fig. 7).
(9) If vehicle is equipped with rear drum brakes,
remove the four bolts attaching the rear brake sup-
port plate to the knuckle (Fig. 9). Next, remove the
brake support plate, brake shoes and wheel cylinder
as an assembly from the rear knuckle, then hang it
out of the way using a wire hanger or cord. Do not
overextend the brake hose when being hung. It is not
necessary to remove the brake hose from the wheel
cylinder when removing the support plate.
(10) If the vehicle is equipped with rear disc
brakes, remove the four bolts mounting the disc
brake adapter to the rear knuckle (Fig. 10). Next,
remove the adapter, rotor shield, parking brake shoes
and parking brake cable as an assembly from the
knuckle, then hang it out of the way using a wire
hanger or cord.Fig. 9 Support Plate Mounting
1 ± BRAKE SHOES
2 ± WHEEL CYLINDER
3 ± KNUCKLE
4 ± BRAKE SUPPORT PLATE MOUNTING BOLTS
5 ± BRAKE SUPPORT PLATE
2 - 42 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

the front side. Install the nut, but do not completely
tighten it at this time. The nut will need to be tight-
ened when the vehicle is at curb height.
(4) Install the rear bayonet bushing on the tension
strut. Be sure the stepped area of the bushing is
squarely seated into the hole in the knuckle.
(5) Install the rear tension strut retainer, then the
nut. To completely install the nut, place a wrench on
the flat formed into the tension strut and tighten the
nut (Fig. 12). Tighten the nut to a torque of 95 N´m
(70 ft. lbs.).
(6) If vehicle is equipped with rear drum brakes,
install the brake support plate on the knuckle and
attach it using it's four mounting bolts (Fig. 9).
Tighten the mounting bolts to a torque of 75 N´m (55
ft. lbs.).
(7) If the vehicle is equipped with rear disc brakes,
install the disc brake adapter on the knuckle and
attach it using it's four mounting bolts (Fig. 10).
Tighten the mounting bolts to a torque of 75 N´m (55
ft. lbs.).
(8) Install the hub and bearing on the knuckle's
spindle, then install a new retaining nut (Fig. 7). Do
not reuse the original nut. Tighten the nut to a
torque of 217 N´m (160 ft. lbs.).
(9) Install the dust cap on the end of the hub and
bearing (Fig. 7).
(10) If the vehicle is equipped with rear disc
brakes (Fig. 7), install the brake rotor and disc brake
caliper on the knuckle. Install the two guide pin bolts
securing the front disc brake caliper to the steering
knuckle. Tighten the guide pin bolts to a torque of 22
N´m (192 in. lbs.).
(11) If the vehicle is equipped with rear drum
brakes, install the screw securing the brake hose
bracket to the rear of the strut assembly (Fig. 5).
Tighten the screw to a torque of 31 N´m (275 in. lbs.).
(12) If the vehicle is equipped with the antilock
brake system (ABS), install the screw securing the
ABS wheel speed sensor bracket to the rear of the
strut assembly (Fig. 6). Tighten the mounting screw
to a torque of 13 N´m (120 in. lbs.).
(13) Install the tire and wheel assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification. Repeat the
tightening sequence, this time, to full specified
torque of 135 N´m (100 ft. lbs.).
(14) Lower the vehicle to ground level.
(15) Tighten the lateral arm-to-knuckle mounting
bolt nut to a torque of 95 N´m (70 ft. lbs.).
(16) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.HUB AND BEARING (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) If the vehicle is equipped with rear drum
brakes, remove any retainer clips from the wheel
mounting studs, then pull the brake drum off the
hub and bearing.
(4) If the vehicle is equipped with rear disc brakes
(Fig. 7), perform the following:
²Remove the two guide pin bolts securing the
front disc brake caliper to the steering knuckle.
²Remove the disc brake caliper from the knuckle
and brake rotor.
²Hang the caliper out of the way using a wire
hanger or cord. Do not support the caliper by letting
it hang by the hydraulic hose.
²Remove any retainer clips from the wheel
mounting studs, then pull the brake rotor off the hub
and bearing.
(5) Remove the dust cap from the hub and bearing
assembly (Fig. 7).
(6) Remove the retaining nut, then the hub and
bearing from the knuckle's spindle (Fig. 7).
INSTALLATION
(1) Install the hub and bearing on the knuckle's
spindle, then install a new retaining nut (Fig. 7). Do
not reuse the original nut. Tighten the nut to a
torque of 217 N´m (160 ft. lbs.).
(2) Install the dust cap on the end of the hub and
bearing (Fig. 7).
(3) If the vehicle is equipped with rear disc brakes
(Fig. 7), install the brake rotor and disc brake caliper
on the knuckle. Install the two guide pin bolts secur-
ing the front disc brake caliper to the steering
knuckle. Tighten the guide pin bolts to a torque of 22
N´m (192 in. lbs.).
(4) Install the tire and wheel assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification. Repeat the
tightening sequence, this time, to full specified
torque of 135 N´m (100 ft. lbs.).
(5) Lower the vehicle to ground level.
2 - 44 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

LATERAL ARMS
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
Use the following procedure for removal and instal-
lation of one or both lateral arms on one side of the
vehicle's rear suspension.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear tire and wheel assembly.
(3) Remove the nut, bolt and washers attaching
both lateral arms to the knuckle (Fig. 1).
(4) Remove nut, washer, bolt and wheel alignment
cam attaching the lateral arms to the rear crossmem-
ber (Fig. 1).
(5) Remove the lateral arms from vehicle.
INSTALLATION
NOTE: Both lateral arms when being installed,
must be specifically positioned and orientated on
the vehicle. The lateral arm that has the same size
bushing sleeves on both ends must be mounted on
the forward side of the crossmember and knuckle
with the trimmed outer edge facing rearward. This
front arm is also marked with the word ªFOR-
WARDº. The side of the arm displaying this must
face forward.
The lateral arm with two different size bushing
sleeves must be mounted on the rearward side of
the crossmember and knuckle. Position the smaller
bushing sleeve end at the knuckle and the larger
bushing sleeve end at the rear crossmember (the
larger bushing sleeve is necessary to accommodate
the rear wheel alignment adjustment cam). If the
rear arm is to be mounted on the right side, the
trimmed outer edge must face rearward. If the rear
arm is to be mounted on the left side, the trimmed
outer edge must face forward.
(1) Following the note above, place the forward lat-
eral arm against the leading end of the knuckle, and
then install the short lateral arm mounting bolt with
a washer through the lateral arm and knuckle and
out the trailing end of the knuckle (Fig. 1).
(2) Following the note above, install the small
bushing sleeved end of the rear lateral arm onto the
end of the bolt just installed through the knuckle
(Fig. 1). Install a washer and nut onto the end of the
mounting bolt, but do not completely tighten the bolt
at this time.(3) Install a wheel alignment adjustment cam on
the long arm mounting bolt.
(4) Hold the rear lateral arm up against the cross-
member and install the long mounting bolt with the
adjustment cam through the lateral arm bushing and
rear crossmember (Fig. 1). The bolt must be installed
with the notch in the adjustment cam pointing
straight up.
(5) Position the forward lateral arm against the
rear crossmember hole. Pass the long mounting bolt
through the lateral arm bushing sleeve.
(6) Install a washer and nut onto the end of lateral
arm mounting bolt at the rear crossmember, but do
not completely tighten the bolt at this time.
NOTE: Once installed, each lateral arm should have
the bow in its length facing downward. Both right
side arms should have the trimmed outer edge fac-
ing toward the rear of the car. Left side arms should
have the trimmed outer edge facing each other. The
mounting bolt at the knuckle should have the nut at
the rear and the mounting bolt at the crossmember
should have the nut at the front (Fig. 13).
(7) Install tire and wheel assembly on the vehicle.
Tighten the wheel mounting nuts in proper sequence
until all nuts are torqued to half specification.
Repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(8) Lower the vehicle to the ground.
(9) With suspension at curb height, tighten the lat-
eral arm mounting bolt nut at the knuckle to 95 N´m
(70 ft. lbs.).
Fig. 13 Lateral Arms
1 ± REAR STABILIZER BAR
2 ± REAR LATERAL ARMS
3 ± RIGHT FRONT LATERAL ARM
4 ± LEFT FRONT LATERAL ARM
PLSUSPENSION 2 - 45
REMOVAL AND INSTALLATION (Continued)

(10) With suspension at curb height, tighten the
lateral arm mounting bolt nut at the crossmember to
88 N´m (65 ft. lbs.).
(11) Set the rear toe on the vehicle to the required
specification as necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
TENSION STRUT
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) Disconnect the tension strut from the knuckle.
To do this, first hold the tension strut from turning
by using a wrench on the flat on the tension strut
and then remove the nut from the rear of the tension
strut (Fig. 14). Next, remove the tension strut
retainer, then the rear tension strut bayonet bushing
from the tension strut.
(4) Remove the nut attaching the parking brake
cable to the stud on the inboard tension strut mount-
ing bolt at the frame (Fig. 15). Remove the parking
brake cable from the stud.
(5) Remove the two mounting bolts holding the
tension bolts to the frame, then remove the tension
strut from the vehicle.(6) Remove the forward bayonet bushing and
retainer from the tension strut.
INSTALLATION
(1) Install the forward retainer and a bayonet
bushing on the tension strut trailing end. Be sure the
stepped area of the bushing is installed to face the
knuckle.
(2) To install the knuckle on the tension, first stick
the trailing end through the hole in the lower end of
the knuckle, seating the bayonet bushing squarely
against the hole. Next, raise the end of the tension
strut with the spool bushing into its mounting posi-
tion on the frame (Fig. 15). Install the mounting
bolts securing the tension strut to the frame.
Remember, the mounting bolt with the stud on the
head is installed on the inboard side.
(3) Tighten the two mounting bolts at the frame to
a torque of 95 N´m (70 ft. lbs.).
(4) Place the parking brake cable routing bracket
on the stud of the inboard mounting bolt and install
the nut securing it in place (Fig. 15). Tighten the nut
to a torque of 28 N´m (250 in. lbs.).
(5) Install the rear bayonet bushing on the tension
strut. Be sure the stepped area of the bushing is
squarely seated into the hole in the knuckle.
(6) Install the rear tension strut retainer, then the
nut. To completely install the nut, place a wrench on
the flat formed into the tension strut and tighten the
nut (Fig. 14). Tighten the nut to a torque of 95 N´m
(70 ft. lbs.).
(7) Install the tire and wheel assembly. Tighten
the wheel mounting nuts in proper sequence until all
Fig. 14 Tension Strut Nut Removal/Installation
1 ± KNUCKLE
2 ± TENSION STRUT
3 ± FLAT
Fig. 15 Tension Strut Mounting At Frame
1 ± TENSION STRUT MOUNTING BOLTS
2 ± TENSION STRUT
3 ± SPOOL BUSHING
4 ± NUT
5 ± PARKING BRAKE CABLE
2 - 46 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

nuts are torqued to half specification. Repeat the
tightening sequence, this time, to full specified
torque of 135 N´m (100 ft. lbs.).
(8) Lower the vehicle to ground level.
(9) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
STABILIZER BAR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both rear wheel and tire assemblies
from the vehicle.
(3) Remove the nut from the end of each rear sta-
bilizer bar link bolt (Fig. 16). Pull the bolt out
through the top of the link and remove the link from
each end of the stabilizer bar.
(4) Remove the two bolts securing each of the two
cushion retainers to the frame rails (Fig. 1), then
remove the cushion retainers, cushions and stabilizer
bar from the vehicle as an assembly.
(5) Pull the cushion retainers off the cushions.
(6) The cushions can be removed from the bar by
utilizing the pre-formed slit in each cushion and peel-
ing it off the bar.
INSTALLATION
(1) Install the cushions on the stabilizer bar by
opening the slit in the cushion and wrapping the
cushion around the bar. When installed properly, the
slit in the cushion should face in the same direction
as the ends of the stabilizer bar, or toward the front
of the car once the bar is installed. The flat side of
each cushion should face upward.
(2) Install the retainers on the cushions, matching
the contour of each retainer with its cushion.
(3) Install the stabilizer bar, cushions and retain-
ers on the car as an assembly. The dipped area in the
center of the bar must face down to clear the well in
the luggage compartment.
(4) Install two bolts in each cushion retainer and
secure the stabilizer bar to the frame of the vehicle
(Fig. 1). Do not completely install the bolts at this
time.
(5) Reinstall each stabilizer bar link (Fig. 1):
²Place the link center sleeve and bushings
between the eye in the end of the stabilizer bar and
the link mounting bracket on the strut.
²Start the stabilizer bar link bolt with bushing
from the top, down through the stabilizer bar, inner
link bushings and sleeve, and strut link mounting
bracket.
²Install a lower bushing, then the nut. Do not
tighten the nut at this time.
(6) Install both tire and wheel assemblies on the
vehicle. Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Repeat the tightening sequence, this
time, to full specified torque of 135 N´m (100 ft. lbs.).
(7) Lower the vehicle to ground level or curb
height.
(8) Tighten the rear stabilizer bar cushion retainer
bolts to a torque of 34 N´m (300 in. lbs.).
(9) Tighten the stabilizer bar link nuts to a torque
of 23 N´m (200 in. lbs.).
(10) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (REAR)
The strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
Refer to REMOVAL AND INSTALLATION in this
section for the required procedure.
For the disassembly and assembly of the strut
assembly, use strut spring compressor, Pentastar Ser-
vice Equipment (PSE) tool W-7200, or the equivalent,
to compress the coil spring. Follow the manufactur-
er's instructions closely.
Fig. 16 Stabilizer Bar Link
1 ± BRAKE HOSE BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
PLSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

DISASSEMBLY
(1) If both struts are being serviced at the same
time, mark the coil spring and strut assembly accord-
ing to which side of the vehicle the strut was
removed from, and which strut the coil spring was
removed from.
(2) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Set the lower, then upper hooks on the
coil spring (Fig. 17). Position the strut clevis bracket
straight inward toward the compressor. Place a
clamp on the lower end of the coil spring, so the strut
is held in place once the strut shaft nut is removed.
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.
(3) Compress the coil spring until all coil spring
tension is removed from the upper mount.(4) Once the spring is sufficiently compressed,
install Strut Nut Socket, Special Tool 6864, on the
strut shaft retaining nut (Fig. 18). Next, install a
socket on the hex on the end of the strut shaft. While
holding the strut shaft from turning, remove the nut
from the strut shaft.
(5) Remove the upper mount from the strut shaft
(Fig. 19).
(6) Remove the clamp from the bottom of the coil
spring and remove the strut out through the bottom
of the coil spring.
(7) Remove the dust shield, then the jounce
bumper from the strut shaft by pulling each straight
up (Fig. 19).
(8) Remove the lower spring isolator from the
lower spring seat located on the strut.
NOTE: If the coil spring needs to be serviced, pro-
ceed with the next step, otherwise, proceed with
step 10.
NOTE: Before removing the coil spring from the
compressor, make not of its position in the com-
pressor, for easy reassembly.
(9) Release the tension from the coil spring by
backing off the compressor drive completely. Push
back the compressor hooks and remove the coil
spring.
(10) Inspect the strut assembly components for the
following and replace as necessary:
²Inspect the strut for any condition of shaft bind-
ing over the full stroke of the shaft.
²Inspect the jounce bumper for cracks and signs
of deterioration.
Fig. 17 Strut Assembly In Compressor
1 ± UPPER HOOKS
2 ± COIL SPRING
3 ± CLEVIS BRACKET
4 ± CLAMP
5 ± LOWER HOOKS
Fig. 18 Shaft Nut Removal/Installation
1 ± UPPER MOUNT
2 ± FRONT HOOK
2 - 48 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

BRAKES
TABLE OF CONTENTS
page page
BASE BRAKE SYSTEM...................... 1ANTILOCK BRAKE SYSTEM................. 65
BASE BRAKE SYSTEM
TABLE OF CONTENTS
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DESCRIPTION AND OPERATION
BASE BRAKE SYSTEM OPERATION...........2
BASE BRAKE SYSTEM COMPONENTS.........2
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM DIAGNOSIS CHARTS....9
POWER BRAKE BOOSTER.................11
DRUM BRAKE AUTOMATIC ADJUSTER........12
BRAKE ROTOR..........................12
BRAKE DRUM...........................15
PROPORTIONING VALVE..................15
BRAKE FLUID CONTAMINATION.............17
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING............17
BASE BRAKE BLEEDING...................17
MASTER CYLINDER BLEEDING.............19
BRAKE TUBE REPAIR.....................19
BRAKE ROTOR MACHINING................21
BRAKE DRUM MACHINING.................22
PARKING BRAKE AUTOMATIC ADJUSTER
LOCK OUT............................22
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........23
BRAKE PEDAL...........................24
BRAKE LAMP SWITCH....................27
MASTER CYLINDER......................28
BRAKE FLUID RESERVOIR.................29
BRAKE FLUID LEVEL SWITCH..............30
POWER BRAKE BOOSTER.................30
PROPORTIONING VALVE..................32
BRAKES TUBES AND HOSES...............33
DISC BRAKE CALIPER (FRONT).............33
DISC BRAKE SHOES (FRONT)..............35BRAKE ROTOR (FRONT)...................37
DISC BRAKE CALIPER (REAR)..............38
DISC BRAKE SHOES (REAR)...............39
BRAKE ROTOR (REAR)....................41
DRUM BRAKE WHEEL CYLINDER (REAR).....41
DRUM BRAKE SHOES (REAR)..............43
BRAKE DRUM (REAR).....................45
DRUM BRAKE SHOE SUPPORT PLATE
(REAR)...............................46
PARKING BRAKE LEVER...................48
PARKING BRAKE CABLE (REAR)............49
PARKING BRAKE SHOES (REAR DISC
BRAKE)...............................53
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER (FRONT AND REAR)....55
CLEANING AND INSPECTION
BRAKE TUBES AND HOSES................59
DISC BRAKES (FRONT)....................59
DISC BRAKES (REAR).....................60
DRUM BRAKES (REAR)....................60
ADJUSTMENTS
BRAKE LAMP SWITCH....................61
DRUM BRAKE SHOES.....................61
PARKING BRAKE SHOES (REAR DISC
BRAKES).............................62
SPECIFICATIONS
BRAKE FLUID...........................63
BRAKE ACTUATION SYSTEM...............63
BRAKE FASTENER TORQUE
SPECIFICATIONS.......................63
SPECIAL TOOLS
BASE BRAKE SYSTEM....................64
PLBRAKES 5 - 1