steering DODGE NEON 2000 Service Owner's Guide

SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STRUT ASSEMBLY:
Tower Nuts............. 34N´m(300 in. lbs.)
Steering Knuckle Nuts.............. 54N´m
(40 ft. lbs.) + 90É Turn
Strut Shaft Nut........... 75N´m(55ft.lbs.)
STEERING KNUCKLE:
Ball Joint Stud Pinch Bolt Nut........ 95N´m
(70 ft. lbs.)
Disc Brake Caliper Guide Bolts........ 22N´m
(192 in. lbs.)
WHEEL BEARING AND HUB:
Bearing Retainer Plate Bolts.......... 28N´m
(250 in. lbs.)
Driveshaft Hub Nut...... 244N´m(180 ft. lbs.)
Wheel Mounting Nuts...........109-150 N´m
(80-110 ft. lbs.)
STEERING GEAR:
Crossmember Bolts........ 68N´m(50ft.lbs.)
Tie Rod Adjusting Jam Nut . . 75 N´m (55 ft. lbs.)
Tie Rod End Steering Knuckle Nut..... 54N´m
(40 ft. lbs.)
LOWER CONTROL ARM:
Front Pivot Bolt......... 163N´m(120 ft. lbs.)
Rear Pivot Bolt......... 203N´m(150 ft. lbs.)
STABILIZER BAR:
Cushion Retainer Bolts.... 28N´m(250 in. lbs.)
Link Nut............... 23N´m(200 in. lbs.)
SPECIAL TOOLS
FRONT SUSPENSION
Socket/Wrench Strut Nut 6864
Remover 6804
Installer 6758
Remover/Installer 6908 (±2)
Installer 6760
Remover MB991113
PLSUSPENSION 2 - 33

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

CAUTION: The strut-to-knuckle attaching bolts are
serrated and must not be turned during removal.
Hold the bolts stationary in the steering knuckle
while removing the nuts, then tap the bolts out
using a pin punch.
(7) Remove the two nuts and bolts attaching the
strut to the rear knuckle (Fig. 1).
(8) Lower the vehicle just enough to access the
luggage compartment without letting the tires touch
the floor. Access to rear upper strut mount attaching
bolts is through the luggage compartment.
(9) Open the deck lid.
(10) If equipped, remove the carpet from the top of
the strut tower.
(11) Loosen, but do not completely remove the 3
nuts securing the strut assembly to the strut tower
(Fig. 8).
Grasp the strut assembly to keep it from moving,
then remove the 3 mounting nuts at the strut tower.
(12) Remove the strut assembly from the knuckle
by sliding it away from the knuckle, lowering it
between the two lateral arms, then tipping the top
outward and removing it out through the well open-
ing.
(13) For disassembly and assembly procedures of
the strut assembly, refer to STRUT ASSEMBLY in
the DISASSEMBLY AND ASSEMBLY section in this
section of this service manual group.
INSTALLATION
(1) To place the strut assembly into mounting posi-
tion, start the lower end of the strut over the top of
the knuckle and down the back between the two lat-
eral arms. Next, lift the top of the strut assembly up
into the strut tower aligning the studs on top of the
upper mount with the three mounting holes in the
strut tower. While holding the strut assembly in
place, install the three mounting nuts on the upper
mount studs inside the luggage compartment (Fig. 8).
Tighten the 3 mounting nuts to a torque of 34 N´m
(300 in. lbs).
(2) Install the carpeting back on top of the rear
strut tower.
(3) Close the deck lid.
(4) Raise the vehicle.
CAUTION: The strut-to-knuckle attaching bolts are
serrated and must not be turned during installation.
Once installed, hold the bolts stationary in the
steering knuckle while installing and tightening the
nuts.
(5) Align the holes in the strut clevis bracket on
the lower end of the strut with the mounting holes in
the knuckle. Install the two bolts attaching the strut
to the rear knuckle (Fig. 1). Install the nuts. Tighten
the two nuts to 88 N´m (65 ft. lbs.).
(6) If the vehicle is equipped with 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.).
(7) Reinstall the stabilizer bar link (Fig. 1):
Fig. 7 Rear Disc Brakes
1 ± DISC BRAKE CALIPER
2 ± DISC BRAKE ADAPTER
3 ± GUIDE PIN BOLTS
4 ± HUB AND BEARING
5 ± BRAKE ROTOR
6 ± RETAINER CLIP
7 ± DUST CAP
8 ± NUT
Fig. 8 Mounting At Strut Tower
1 ± UPPER MOUNT
2 ± MOUNTING NUTS
3 ± STRUT TOWER
PLSUSPENSION 2 - 41
REMOVAL AND INSTALLATION (Continued)

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)

CAUTION: The strut-to-knuckle attaching bolts are
serrated and must not be turned during removal.
Hold the bolts stationary in the steering knuckle
while removing the nuts, then tap the bolts out
using a pin punch.
(11) Loosen, but do not completely remove the two
nuts and bolts attaching the rear knuckle to the
strut (Fig. 11).
(12) Remove the nuts and bolt attaching the rear
knuckle to the lateral arms (Fig. 11).(13) 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. 12). Next, remove the tension strut
retainer, then the rear tension strut bayonet bushing
from the tension strut.
(14) Remove the two nuts and bolts attaching the
rear knuckle to the strut (Fig. 11). Tap the bolts from
the knuckle using a pin punch.
(15) Remove the knuckle.
INSTALLATION
(1) To install the knuckle on the vehicle, first align
the hole in the lower end of the rear knuckle with
the forward bayonet bushing on the tension strut. Be
sure the stepped area of the bushing is squarely
seated into the hole in the knuckle. Next, Rotate the
knuckle until the upper mounting holes in the
knuckle is aligned with the holes in the strut's clevis
bracket.
CAUTION: The strut-to-knuckle attaching bolts are
serrated and must not be turned during installation.
Once installed, hold the bolts stationary in the
steering knuckle while installing and tightening the
nuts.
(2) Install the two bolts attaching the strut to the
rear knuckle from the front side. Install the nuts on
the bolts (Fig. 11). Tighten the two nuts to a torque
of 88 N´m (65 ft. lbs.).
(3) Align the lateral arms with the hole in the cen-
ter of the knuckle. Install the bolt attaching the arms
to the knuckle. When installing the bolt, start it from
Fig. 10 Disc Brake Adapter Mounting
1 ± DISC BRAKE ADAPTER
2 ± KNUCKLE
3 ± MOUNTING BOLTS
Fig. 11 Rear Knuckle Mounting
1 ± STRUT ASSEMBLY
2 ± KNUCKLE
3 ± LATERAL ARMS
4 ± NUT
5 ± NUTS
Fig. 12 Tension Strut Nut Removal/Installation
1 ± KNUCKLE
2 ± TENSION STRUT
3 ± FLAT
PLSUSPENSION 2 - 43
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)

Driveshafts used on both the right and left sides of
the vehicle use a tuned rubber damper weight
mounted to the interconnecting shaft (Fig. 1). The
damper weight applications vary by which side of the
vehicle the driveshaft is located on and the transmis-
sion application of the vehicle. When replacing a
driveshaft, be sure the replacement driveshaft has
the same damper weight as the original.
Both driveshaft assemblies use the same type of
inner and outer joints. The inner joint of both drive-
shaft assemblies is a tripod joint, and the outer joint
of both driveshaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (C/V) joint assemblies. The inner tripod joint
allows for the changes in driveshaft length through
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 single
piece steel hub nut (Fig. 2). The hub nut is a locking
style; the nut lock, anti-rattle washer, and cotter pin
are not necessary.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.
Fig. 2 Driveshaft Retaining Nut
1 ± DRIVESHAFT
2 ± HUB
3 ± HUB NUT
3 - 2 DIFFERENTIAL AND DRIVELINEPL
DESCRIPTION AND OPERATION (Continued)

(7) Remove nut and bolt (Fig. 5) 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.
(8) Separate ball joint stud from steering knuckle
by prying down on lower control arm (Fig. 6).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.
(9) Remove driveshaft from steering knuckle by
pulling outward on knuckle while pressing in on
driveshaft. Support outer end of driveshaft assembly.
If difficulty in separating driveshaft from steering
knuckle is encountered, perform the following proce-
dure:
(a) Install Puller, Special Tool 6790 on hub and
bearing assembly (Fig. 7), using wheel lug nuts to
secure it in place.
(b) 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 driveshaft outer stub axle from the hub
and bearing assembly (Fig. 8).
(c) Pull steering knuckle assembly out and away
from outer C/V joint of the driveshaft assembly as
shown in (Fig. 5).
(10) 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.
Fig. 5 Steering Knuckle at Lower Control Arm Ball
Joint
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
Fig. 6 Separating Lower Control Arm from Steering
Knuckle
1 ± STEERING KNUCKLE
2±PRYBAR
3 ± LOWER CONTROL ARM
4 ± BALL JOINT STUD
Fig. 7 Puller Installed On Hub/Bearing Assembly
1 ± TOOL 6790
3 - 4 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

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.
(4) Clean all debris and moisture out of steering
knuckle (Fig. 12).
(5) Ensure that front of outer C/V joint, which fits
into steering knuckle (Fig. 13), 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. 14).
NOTE: At this point, the outer joint will not seat
completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.
(7) Install aNEWsteering knuckle to ball joint
stud bolt and nut (Fig. 14). Tighten the nut and bolt
to 95 N´m (70 ft. lbs.).
Fig. 12 Steering Knuckle to C/V Joint Sealing Area
1 ± STEERING KNUCKLE
2 ± WHEEL BEARING
3 ± FRONT HUB
4 ± THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE
OF ALL DEBRIS AND MOISTURE BEFORE INSTALLING
DRIVE SHAFT IN STEERING KNUCKLE
Fig. 13 Outer C/V Joint Inspection
1 ± OUTER C/V JOINT
2 ± THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
Fig. 14 Driveshaft Installation Into Hub And Steering
Knuckle
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
3 - 6 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

Proportioning valves balance front to rear braking
by controlling the brake fluid hydraulic pressure to
the rear brakes. Under light pedal application, the
proportioning valve allows normal fluid flow to the
rear brakes. Under higher pedal effort, the valve
reduces fluid pressure to the rear brakes.
The non-antilock master cylinder is a four-outlet
design with two screw-in proportioning valves
attached directly to the master cylinder housing (Fig.
3). One proportioning valve controls each rear brake.
BRAKE TUBES AND HOSES
The purpose of the brake tubes and flex hoses is to
transfer the pressurized brake fluid developed by the
master cylinder to the brakes at each wheel of the
vehicle. The flex hoses connect the chassis brake
tubes, which are mounted to the vehicle's underbody,
to the brake at each wheel, allowing for movement of
the vehicle's suspension. The brake tubes are steel
with a corrosion-resistant nylon coating applied to
the external surfaces. The flex hoses are made of
reinforced rubber.
DISC BRAKES (FRONT)
The front disc brakes consist of the following com-
ponents (Fig. 4):
²Brake caliper - single-piston, floating type
²Brake shoes and linings
²Brake rotorWhen the brakes are applied, fluid pressure is sent
to each brake caliper. The pressure at the caliper is
exerted equally against the caliper piston. The pres-
sure applied to the piston is transmitted directly to
the inboard brake shoe. This forces the shoe lining
against the inner surface of the brake rotor. At the
same time, fluid pressure within the caliper piston
bore forces the caliper to slide inward on its guide
pins. This action brings the outboard shoe lining into
contact with the outer surface of the brake rotor.
This pressure on both sides of the brake rotor causes
friction, bringing the vehicle to a stop.
BRAKE CALIPER
The caliper is a one-piece casting with the inboard
side containing a single piston cylinder bore (Fig. 5).
The front disc brake caliper piston, is manufac-
tured from a phenolic compound. The outside diame-
ter 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. 6). 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.
A rubber dust boot is installed in the cylinder bore
opening and in a groove in the piston (Fig. 6). This
prevents contamination in the bore area.
The caliper is mounted to the steering knuckle
using bushings, sleeves and two guide pin bolts (Fig.
5). The guide pin bolts thread directly into bosses on
the steering knuckle.
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. All of the front brake force generated during
braking of the vehicle is taken up directly by the
steering knuckles of the vehicle.
BRAKE SHOES AND LININGS
There are two brake shoes mounted to each caliper,
one inboard and one outboard (Fig. 5). When brake
shoes are replaced, only brake shoes meeting the
original equipment manufacturer (OEM) formulation
(such as Mopartreplacement parts) should be used.
As front disc brake shoe linings wear, master cyl-
inder reservoir brake fluid level will drop. Fluid level
should be checked after replacing shoes.
Front disc brakes are equipped with an audible
wear indicator on the outboard brake pad (Fig. 5).
This sensor emits a sound when the brake lining
may need inspection or replacement.
Fig. 4 Front Disc Brakes
1 ± STEERING KNUCKLE
2 ± BRAKE PADS AND LININGS
3 ± BRAKE ROTOR
4 ± DRIVING HUB
5 ± CALIPER ASSEMBLY
5 - 4 BRAKESPL
DESCRIPTION AND OPERATION (Continued)