DODGE NEON 2000 Service Service Manual

(4) Using the hydraulic press, press the ball joint
completely out of the lower control arm, into the
receiver.
(5) Remove the tools, ball joint and arm from the
hydraulic press.
ASSEMBLY
CAUTION: When installing a ball joint in its mount-
ing hole in the lower control arm, position the ball
joint so the notch in the ball joint stud is facing the
lower control arm front isolator bushing (Fig. 45).
This will ease assembly of the ball joint to the
steering knuckle when the installation of the pinch
bolt is attempted.(1) By hand, position ball joint into it's bore on the
lower control arm (Fig. 45). To avoid binding upon
installation, be sure the ball joint is not cocked in the
bore.
(2) Position the Installer, Special Tool 6758, on a
hydraulic press to support the lower control arm
(Fig. 46). Place the control arm on top of Tool 6758 in
the upside-down position, aligning the ball joint stud
squarely with the Installer's cup.
(3) Place the larger end of the Adapter, Special
Tool 6804, on top of the ball joint as shown (Fig. 46).
(4) Using the hydraulic press, press the ball joint
into the lower control arm until the shoulder on the
Fig. 43 Seal Boot Removal
1±TOOL
2 ± SEAL BOOT
3 ± LOWER CONTROL ARM
Fig. 44 Ball Joint Removal
1 ± PRESS
2 ± BALL JOINT
Fig. 45 Ball Joint Alignment
1 ± BALL JOINT STUD
2 ± NOTCH
3 ± LOWER CONTROL ARM
4 ± FRONT ISOLATOR BUSHING
Fig. 46 Ball Joint Installation
1 ± PRESS
2 ± BALL JOINT
2 - 30 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

ball joint bottoms against the lower control arm ball
joint bore. Do not apply excessive pressure against
ball joint and lower control arm once the ball joint
bottoms.
(5) Remove the tools and arm from the hydraulic
press.
CAUTION: When installing the sealing boot on the
ball joint, position the upward lip on the outside
perimeter of the seal boot outward, away from the
control arm once installed (Fig. 47). It is there to
help shield heat from the sealing boot.
(6) Place a new ball joint seal boot over the ball
joint stud. The upward lip located on the outside
perimeter of the seal boot must point outward away
from the control arm once installed (Fig. 47). Start
the sealing boot over the sides of the ball joint by
hand.
(7) Position the Installer, Special Tool 6758, over
the sealing boot outer diameter as shown (Fig. 47).
By hand, apply pressure to the top of the Installer
until the seal boot is pressed squarely down against
the top surface of lower control arm.
(8) Remove the tool.
(9) Install the lower control arm on the vehicle.
Refer to LOWER CONTROL ARM in the REMOVAL
AND INSTALLATION section.
NOTE: If the ball joint is equipped with a lubeable
grease fitting, the joint will need to be lubricated
once the lower control arm installation is complete.LOWER CONTROL ARM (REAR ISOLATOR
BUSHING)
NOTE: The removal and installation of the rear iso-
lator bushing from the lower control arm is only to
be done with the lower control arm removed from
the vehicle. Refer to LOWER CONTROL ARM in the
REMOVAL AND INSTALLATION section. The front
isolator bushing is not serviceable.
DISASSEMBLY
(1) Install the Remover Receiver, Special Tool
8373-1, into the cup of the Ball Joint Press, Special
Tool C-4212F, and tighten the set screw. Install the
Remover Driver, Special Tool 8373-2, on the tip of the
Ball Joint Press screw-drive.
(2) Place the lower control arm outer flange
against the Receiver as shown (Fig. 48). Tighten the
screw-drive until the Driver contacts the outer cir-
cumference of the bushing evenly (Fig. 48). Continue
to tighten the screw-drive until the bushing is
pressed completely out of the lower control arm.
(3) Back off the screw-drive and remove the lower
control arm and isolator bushing from the Receiver.
(4) Remove the driver 8373-2 and receiver 8373-1
from the ball joint press C-4212F.
Fig. 47 Seal Boot Installation
1 ± SEAL BOOT UPWARD LIP
2 ± BALL JOINT
Fig. 48 Removing Bushing
1 ± CONTROL ARM ISOLATOR BUSHING
2 ± FLANGE
PLSUSPENSION 2 - 31
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
(1) Back the ball joint press C-4212F set screw
outward so it does not extend out into the cup area
(Fig. 49).
(2) Start the bushing in the lower control arm
bushing bore by hand. Position the bushing so the
voids in the rubber are aligned in relationship to the
ball joint as shown (Fig. 50).
(3) Install the Receiver, Special Tool 6760, on the
tip of the Ball Joint Press screw drive.
(4) Place the lower control arm flange against the
cup area of the ball joint press and tighten the screw-drive until the Receiver contacts the outer circumfer-
ence of the bushing (Fig. 51). Slowly tighten the
screw-drive until the bushing bottoms in the lower
control arm bushing bore.
(5) Back off the Ball Joint Press screw-drive and
remove the power steering gear from the press.
(6) Install the lower control arm on the vehicle.
Fig. 49 Set Screw Backed Outward
1 ± SET SCREW
2 ± CUP AREA
Fig. 50 Aligning Bushing With Ball Joint
1 ± BALL JOINT
2 ± VOIDS
3 ± REAR ISOLATOR BUSHING
Fig. 51 Installing Bushing
1 ± LOWER CONTROL ARM FLANGE
2 ± ISOLATOR BUSHING
2 - 32 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

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

Splitter Bearing 1130
Remover MB-990799
Remover/Installer 6644 (-2)
Installer Bearing 5052
Installer Adapter C-4698-2
Remover C-4150A
2 - 34 SUSPENSIONPL
SPECIAL TOOLS (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

Fig. 1 Rear Suspension System
2 - 36 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

For more information on the description and oper-
ation of an individual component, refer to the appli-
cable component heading in this section.
STRUT ASSEMBLY (REAR)
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around
struts. The coil springs are contained between the
upper mount of the strut assembly and a lower
spring seat on the body of the strut.
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 with prevailing torque
nuts.
The rear strut assembly includes the following
components (Fig. 1): A rubber isolated upper mount,
a dust shield, a jounce bumper, a coil spring, a lower
spring isolator, and a strut. Any component in need
of service requires removal of the strut assembly
from the vehicle and disassembly of it.
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. If a coil spring
requires replacement, be sure the spring needing
replacement is replaced with a spring meeting the
correct load rating for the vehicle with its specific
options.
KNUCKLE (REAR)
A forged rear knuckle bolts to each rear strut
assembly (Fig. 1). The rear knuckle's spindle sup-
ports the rear hub and bearing. Together they sup-
port the rear tire and wheel. The movement of the
rear knuckle is controlled laterally using two lateral
arms attached to the knuckle. Fore and aft move-
ment of the knuckle is controlled by using a tension
strut.
HUB AND BEARING (REAR)
The hub and bearing is mounted on the rear
knuckle's spindle (Fig. 1). The hub and bearing
adapts the tire and wheel assembly to the knuckle.
It's bearing allows the tire and wheel assembly to
rotate freely on the vehicle.
All vehicles are equipped with permanently lubri-
cated and sealed for life rear wheel bearings. There
is no periodic lubrication or maintenance recom-
mended for these units.
The only servicable components of the hub and
bearing are the wheel mounting studs.
If a vehicle is equipped with antilock brakes, the
tone wheels for the rear wheel speed sensors are
pressed onto the hub.
LATERAL ARMS
The lateral arms control the lateral movement of
the rear suspension, specifically the knuckle (Fig. 1).
There are two lateral arms per side of the rear sus-
pension. One arm is attached to the front end of the
knuckle and the other is attached to the rear of the
knuckle. The other end of each lateral arm attaches
to the rear crossmember.
Visually it appears that the left rear arm is
mounted backwards in relation to the other arms
(Fig. 2). Although the left rear arm looks like it is
same as the right rear arm, just reversed, it is not
the same; the arms are not interchangeable.
The front arms are interchangeable, but should be
mounted with the side displaying the word ªFOR-
WARDº stamped into it toward the front of the vehi-
cle. The trimmed outer edge of the arms will then be
facing the rear of the vehicle.
1 ± VEHICLE STRUT TOWER
2 ± STRUT ASSEMBLY
3 ± TENSION STRUT
4 ± LATERAL ARMS
5 ± KNUCKLE
6 ± HUB AND BEARING
7 ± WHEEL ALIGNMENT ADJUSTMENT CAM
8 ± STRUT9 ± LOWER SPRING ISOLATOR
10 ± COIL SPRING
11 ± STABILIZER BAR
12 ± JOUNCE BUMPER
13 ± DUST SHIELD
14 ± UPPER MOUNT
15 ± STABILIZER BAR LINK
16 ± STABILIZER BAR CUSHION AND RETAINER
PLSUSPENSION 2 - 37
DESCRIPTION AND OPERATION (Continued)

The lateral arms are made of stamped steel and
have rubber isolator bushings at each end. The lat-
eral arms are attached to the rear crossmember and
knuckle using a unique bolt and nut assembly at
each end. The lateral arm-to-rear crossmember
attaching bolts are longer than the lateral arm-to-
knuckle attaching bolts. Each lateral arm to knuckle
attaching bolt and nut assembly uses two flat wash-
ers. Each lateral arm to rear crossmember attaching
bolt uses one flat washer and one adjustment cam to
provide a means for rear wheel alignment toe adjust-
ment.
TENSION STRUT
The tension strut controls the fore-and-aft move-
ment of the rear knuckle (Fig. 1).
There is one tension strut per side of the rear sus-
pension. The leading end of the tension strut
attaches to the frame rail while the trailing end of
the strut attaches to the lower end of the rear
knuckle. The tension strut is isolated from the rest of
the rear suspension through the use of rubber bush-
ings located at each end. The rear bushings (bayonet
type) can be serviced separately, the front bushings
(spool type) cannot.
STABILIZER BAR (REAR)
The stabilizer bar interconnects both rear strut
assemblies and is attached to the rear frame rails of
the vehicle (Fig. 3).
The rear stabilizer bar allows jounce and rebound
movements affecting one wheel to be partially trans-
mitted to the opposite wheel of the vehicle to stabi-
lize body roll.Attachment of the stabilizer bar to the rear frame
rails of the vehicle is through two rubber-isolator
cushions and retainers (Fig. 1). The stabilizer bar
attachment to each strut assembly is done utilizing a
rubber isolated stabilizer bar link. All parts of the
stabilizer bar are serviceable, and the stabilizer bar
to frame rail isolator cushions are split for easy
removal and installation.
DIAGNOSIS AND TESTING
STRUT ASSEMBLY (REAR)
Inspect the strut assembly for the following condi-
tions (Fig. 4):
²Inspect for a damaged or broken coil spring.
²Inspect for a torn or damaged strut assembly
dust shield.
²Lift the dust shield and inspect the strut assem-
bly for evidence of fluid running from the upper end
of the strut fluid reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit.) A slight amount of seepage
between the strut shaft and strut shaft seal is not
unusual and does not affect performance of the strut
assembly.
²Lift the dust shield and inspect the jounce
bumper for signs of damage or deterioration.
Fig. 2 Lateral Arms
1 ± REAR STABILIZER BAR
2 ± REAR LATERAL ARMS
3 ± RIGHT FRONT LATERAL ARM
4 ± LEFT FRONT LATERAL ARM
Fig. 3 Rear Stabilizer Bar
1 ± REAR STABILIZER BAR
2 ± REAR LATERAL ARMS
3 ± RIGHT FRONT LATERAL ARM
4 ± LEFT FRONT LATERAL ARM
2 - 38 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

KNUCKLE (REAR)
The rear knuckle is not a repairable component of
the rear suspension. Upon visual inspection, if it is
determined that the knuckle is cracked, bent or bro-
ken, no attempt is to be made to repair or to
straighten the knuckle. The knuckle must be
replaced if found to be damaged in any way.
HUB AND BEARING (REAR)
The hub and bearing is designed for the life of the
vehicle and requires no type of periodic maintenance
(Fig. 1). The following procedure may be used for
diagnosing the condition of the hub and bearing.
With the wheel, disc brake rotor or brake drum
removed, rotate the hub. Any roughness or resistance
to rotation may indicate dirt intrusion or a failed hub
bearing. If the bearing exhibits any of these condi-
tions during diagnosis, the hub and bearing will
require replacement. The bearing is not serviceable
alone.
Damaged bearing seals and the resulting excessive
grease loss may also require hub and bearing
replacement. Moderate grease weapage from thebearing is considered normal and should not require
replacement of the wheel bearing.
To diagnose a bent hub, refer to BRAKE ROTOR in
the DIAGNOSIS AND TESTING section in the
BRAKES service manual group for the procedure on
measuring hub runout.
LATERAL ARMS
Inspect each lateral arm (Fig. 1). Look for signs of
contact with an object that has caused damage to the
lateral arm. If the lateral arm is bent or damaged,
the lateral arm will require replacement. Do not
attempt to repair or straighten a lateral arm.
Inspect the lateral arm isolator bushings and their
sleeves for signs of damage or deterioration. If dam-
age or deterioration is present, replacement of the
entire lateral arm will be required. The isolator
bushings cannot be serviced separately from the lat-
eral arms.
TENSION STRUT
Inspect the tension strut (Fig. 1). Look for signs of
contact with any object that 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.
Inspect the tension strut front (spool type) bushing,
and rear (bayonet type) bushings and retainers for
signs of deterioration or damage. If the front bushing
is damaged or shows signs of deteriation, the tension
strut must be replaced. The front bushing cannot be
replaced separately. If the rear bushings are deterio-
rated or damaged, or the retainers are damaged,
replacement is necessary. The bushings and retainers
can be replaced separately from the tension strut.
STABILIZER BAR (REAR)
Inspect the stabilizer bar (Fig. 1). Look for damage
or bending. If damage is evident, the bar must be
replaced.
Inspect for broken, cracked or distorted stabilizer
bar cushions and cushion retainers. The horizontal
slit at the front of each cushion is supposed to be
there. If damage is evident, the cushions can be
replaced separately from the stabilizer bar utilizing
the horizontal slit.
Inspect the stabilizer bar links that attach the sta-
bilizer bar to each rear strut. Look for damage or
deterioration of the bushings on the ends of each
link. Inspect the stabilizer bar link to ensure it is not
bent or broken. If any of these conditions are present,
the stabilizer bar link must be replaced. The links
can be replaced separately from the stabilizer bar.
Fig. 4 Strut Assembly
1 ± STRUT ASSEMBLY
2 ± STRUT
3 ± LOWER SPRING ISOLATOR
4 ± COIL SPRING
5 ± JOUNCE BUMPER
6 ± DUST SHIELD
7 ± UPPER MOUNT
PLSUSPENSION 2 - 39
DIAGNOSIS AND TESTING (Continued)