1999 DODGE NEON Service Repair Manual

pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
REMOVAL AND INSTALLATION
MANUAL AND POWER STEERING GEAR
The removal and replacement procedure for both
the manual and power steering gears is the same.
The only additional steps of the procedure for the
power steering gear, is the removal and replacement
of the power steering fluid lines at the steering gear.
REMOVE
(1) From interior of vehicle, disconnect the steer-
ing gear coupler, from the steering column shaft cou-
pler (Fig. 4).
(2) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(3) Remove both front wheel and tire assemblies
from the vehicle.
(4) Remove engine/transaxle bobble dampener, on
vehicles so equipped, from front suspension cross-
member (Fig. 5). Bobble strut does not need to be
removed from transaxle assembly.
(5) Remove nuts attaching both outer tie rod ends
to the steering knuckles (Fig. 6).Nuts are to be
removed from tie rod ends using the following
procedure, hold tie rod end stud with an 11/32
socket, while loosening and removing nut with
wrench.
(6) Remove tie rod ends from steering knuckles
using Remover, Special Tool MB-991113 (Fig. 7).(7) If equipped, remove vehicle wiring harness con-
nector from the power steering fluid pressure switch
(Fig. 8).
Fig. 4 Steering Column To Steering Gear Coupler
Fig. 5 Engine/Transaxle Bobble Dampener
Fig. 6 Removing Tie Rod End Attaching Nut
Fig. 7 Tie Rod End Removal From Steering Knuckle
19 - 28 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

(8) If vehicle is equipped with power steering,
remove power steering pressure and return hose
routing bracket from front suspension crossmember
(Fig. 9).The hose routing bracket does not have
to be removed from the power steering pres-
sure and return hoses.
(9) If vehicle is equipped with power steering,
remove power steering fluid, pressure and return
hoses (Fig. 10) from the power steering gear assem-
bly.
NOTE: This vehicle is designed and assembled
using NET BUILD front suspension alignment set-
tings. This means that front suspension alignment
settings are determined as the vehicle is designed
by the location of front suspension components in
relation to the vehicle body. This process is carried
out when building the vehicle, by accurately locat-
ing the front suspension crossmember, to mastergage holes located in the underbody of the vehicle.
With this method of designing and building a vehi-
cle, it is no longer possible to adjust a vehicles
front suspension alignment settings to the required
specifications. Due to this, whenever the front sus-
pension crossmember is removed from a vehicle, it
MUST be replaced in the same location on the body
of the vehicle it was removed from. Front suspen-
sion Toe settings though are still adjustable by the
outer tie rod ends.
CAUTION: Before removing front suspension
crossmember from the vehicle, the location of the
front suspension crossmember MUST be scribbed
on body of vehicle per (Fig. 9). This must be done
so crossmember can be relocated against body of
vehicle in the same location when it is reinstalled. If
location of front suspension crossmember to body
of vehicle is not maintained when vehicle is assem-
bled, NET BUILD front suspension alignment set-
tings will not be obtained. This may lead to
handling and or tire wear problems.
(10) Using an awl, scribe a line (Fig. 11) marking
the location of where front suspension crossmember
is mounted against the body of the vehicle.
(11) Position a transmission jack under the center
of the front suspension crossmember (Fig. 12). Trans-
mission jack is used to lower, support and raise front
suspension crossmember when removing steering
gear assembly.
(12) Loosen and fully remove the front 2 bolts (Fig.
13) attaching front suspension crossmember to frame
rails of vehicle. Then loosen the 2 rear bolts (Fig. 13)
attaching front suspension crossmember and lower
control arm to body of vehicle.Lower front suspen-
sion crossmember while loosening rear bolts,
Fig. 8 Power Steering Fluid Pressure Switch
Electrical Connector
Fig. 9 Power Steering Pressure And Return Hose
Routing Bracket
Fig. 10 Power Steering Fluid Pressure And Return
Hoses
PLSTEERING 19 - 29
REMOVAL AND INSTALLATION (Continued)

but do not remove rear bolts from crossmem-
ber.(13) Using transmission jack, lower front suspen-
sion crossmember enough to allow steering gear to be
removed from crossmember (Fig. 14).When lower-
ing front suspension crossmember, do not let
crossmember hang from lower control arms
weight of crossmember should be supported by
transmission jack.
(14) Loosen and remove the 4 bolts (Fig. 15),
attaching steering assembly to front suspension
crossmember. Then remove the steering gear assem-
bly from the front suspension crossmember.
(15) Transfer required parts from removed steering
gear assembly to the replacement steering gear, if a
new steering gear is being installed.
INSTALL
(1) Install steering gear assembly on front suspen-
sion crossmember. Install the 4 steering gear assem-
bly to front crossmember mounting bolts (Fig. 15).
Fig. 11 Marking Front Suspension Crossmember
Location
Fig. 12 Supporting Front Suspension Crossmember
Fig. 13 Front Suspension Crossmember Mounting
Bolts
Fig. 14 Crossmember Lowered For Removal Of
Steering Gear
Fig. 15 Steering Gear Assembly Mounting Bolts
19 - 30 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

Torque the 4 steering gear mounting bolts to 68 N´m
(50 ft. lbs.).
(2) Using the transmission jack, raise front sus-
pension crossmember and steering gear against body
and frame rails of vehicle. Start the 2 rear bolts into
tapping plates, attaching front suspension crossmem-
ber to body of vehicle (Fig. 13). Then install the 2
front bolts, attaching front suspension crossmember
to frame rails of vehicle (Fig. 13). Tighten the 4
mounting bolts, until front suspension crossmember
is against body of vehicle at the 4 mounting points.
Then torque the 4 mounting bolts to 2 N´m (20 in.
lbs.) to hold front suspension crossmember in posi-
tion.
CAUTION: When front suspension crossmember is
installed back in vehicle, crossmember MUST be
aligned with positioning marks previously scribbed
into body of vehicle (Fig. 16). This MUST be done to
maintain NET BUILD front suspension alignment
settings.
(3) Using a soft face hammer, tap front suspension
crossmember into position, until it is aligned with
the 2 previously scribbed positioning marks on body
of vehicle (Fig. 16). When front suspension cross-
member is correctly positioned, torque the 2 rear
crossmember/lower control arm mounting bolts to
163 N´m (120 ft. lbs.). Then torque the 2 front cross-
member to frame rail attaching bolts to 163 N´m (120
ft. lbs.) (Fig. 13).
(4) If vehicle is equipped with power steering,
install power steering fluid pressure and return
hoses into correct fluid ports on power steering gear
assembly (Fig. 10). Torque power steering fluid pres-
sure and return lines to steering gear tube nuts (Fig.
10) to 31 N´m (275 in. lbs.).(5) If vehicle is equipped with power steering,
install power steering pressure and return hose rout-
ing bracket and attaching screw on front suspension
crossmember (Fig. 9). Torque hose routing bracket to
crossmember attaching bolt (Fig. 9) to 23 N´m (17 ft,
lbs.).
(6) If the vehicle is equipped with power steering,
install vehicle wiring harness connector onto power
steering fluid pressure switch on steering gear
assembly (Fig. 8). Be sure locking tab on wiring har-
ness connector is securely latched to pressure switch.
(7) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 6). Then using a crowfoot
and 11/32 socket (Fig. 17), torque tie rod end attach-
ing nut to 55 N´m (40 ft. lbs.).
(8) Install engine/transaxle bobble strut (Fig. 5)
back on front suspension crossmember bracket.
Install and securely tighten the dampener to cross-
member attaching bolt.
(9) Install the wheel and tire assemblies back on
vehicle. Tighten the wheel nuts to 135 N´m (100 ft.
lbs.) torque.
(10) Lower vehicle.
(11) From interior of vehicle, reconnect the steer-
ing gear coupler with the steering column shaft cou-
pler. Install steering gear coupler retaining pinch bolt
and torque to 28 N´m (250 in. lbs.).Be sure to
install the upper to lower steering coupler
retaining bolt, retention pin (Fig. 4).
CAUTION: Do not use automatic transmission
fluid.
(12) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level.
Fig. 16 Crossmember Aligned With Positioning
Marks
Fig. 17 Torquing Tie Rod End Attaching Nut
PLSTEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)

(13) Start the engine and let run for a few seconds.
Then turn the engine off.
(14) Add fluid if necessary.
(15) Raise front wheels of vehicle off the ground.
(16) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks.Fill pump reservoir to correct
level with Mopart, Power Steering Fluid, or
equivalent.See Checking Fluid Level.
(17) Lower front wheels of vehicle back on the
ground.
CAUTION: During this procedure do not allow the
steering gear inner tie rod boots to become twisted.
(See Wheel Alignment in the suspension section of
this service manual).
(18) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
(19) Tighten tie rod jam nut (Fig. 18) to 61 N´m
(45 ft.lbs.) torque.
(20) Adjust steering gear to tie rod boots at tie
rods.
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD
DISASSEMBLE
(1) Loosen the inner tie rod to outer tie rod jam
nut (Fig. 19). Thread the jam nut far enough up the
inner tie rod to pull the collar (Fig. 19) away fromthe outer tie rod end. Pull the collar off the end of
the outer tie rod.
(2) Remove the nut attaching the outer tie rod end
to steering knuckle (Fig. 20).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(3) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 21) .
(4) Remove outer tie rod from inner tie rod by un-
threading it from the inner tie rod.
ASSEMBLE
(1) Install the jam nut (Fig. 19) on inner tie rod
end.
Fig. 18 Outer Tie Rod End Jam Nut
Fig. 19 Outer Tie Rod
Fig. 20 Removing /Installing Tie Rod End Attaching
Nut
19 - 32 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

NOTE: Be sure the collar is installed on the inner
tie rod with the flat end of the collar against jam nut
and the open end of the collar facing the outer tie
rod end.
(2) Install the collar (Fig. 19) on the inner tie rod.
(3) Install outer tie rod onto inner tie rod (Fig. 19).
(4) Position the collar around the end of the outer
tie rod (Fig. 19).
(5) Thread the jam nut down the inner tie far
enough to hold the collar in place on the outer tie
rod. Do not tighten jam nut.
(6) Install the tie rod end into the steering
knuckle. Start tie rod end to steering knuckle attach-
ing nut onto stud of tie rod end. While holding stud
of tie rod end stationary, tighten tie rod end to steer-
ing knuckle attaching nut (Fig. 20). Then using a
crowfoot and 11/32 socket (Fig. 22), torque the tie rod
end attaching nut to 61 N´m (45 ft. lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See WheelAlignment in the suspension section of this service
manual).
(7) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
CAUTION: Prior to tightening the jam nut to the
specified torque, check the orientation of the collar
to be sure it is in the proper position to fit up
against the outer tie rod end.
(8) Torque the tie rod jam nut (Fig. 19) to a torque
of 55 N´m (40 ft. lbs.) torque.
(9) Adjust the steering gear to inner tie rod boots
at inner tie rod if they became twisted during Toe
adjustment.
Fig. 22 Torquing Tie Rod End Attaching NutFig. 21 Tie Rod End Removal From Steering
Knuckle
PLSTEERING 19 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
FRONT SUSPENSION CROSSMEMBER:
To Body Mounting Bolts......163 N´m (120 ft. lbs.)
STEERING GEAR:
To Crossmember Mounting Bolts .68 N´m (50 ft. lbs.)
OUTER TIE ROD:
To Steering Knuckle Nut.......55N´m(40ft.lbs.)
To Inner Tie Rod Jam Nut......61N´m(45ft.lbs.)
POWER STEERING HOSE:
Tube Nuts.................31N´m(275 in. lbs.)
Routing Bracket At Crossmember .23 N´m (17 ft. lbs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover Tie Rod End MB±990635
P/S System Analyzer 6815
19 - 34 STEERINGPL

STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION
STEERING COLUMN ASSEMBLY............ 35
STEERING GEAR TO STEERING
COLUMN COUPLING................... 36
DIAGNOSIS AND TESTING
STEERING COLUMN TO STEERING
GEAR COUPLING...................... 36
STEERING COLUMN..................... 36REMOVAL AND INSTALLATION
STEERING COLUMN SERVICE
PROCEDURE WARNINGS............... 37
STEERING COLUMN..................... 38
SPECIFICATIONS
STEERING COLUMN FASTEER
TORQUE SPECIFICATIONS.............. 42
DESCRIPTION AND OPERATION
STEERING COLUMN ASSEMBLY
Both the standard non-tilt and tilt steering col-
umns (Fig. 1) have been designed to be serviced only
as complete assemblies, if a component of the steer-
ing column is defective. The only replaceable compo-nents of the steering column assembly, are the key
cylinder, ignition switch, multi- function switch, clock
spring, trim shrouds and steering wheel. These
replaceable components of the steering column can be
serviced without requiring removal of the steering
column from the vehicle.
Fig. 1 Non-Tilt And Tilt Steering Column Assemblies
PLSTEERING 19 - 35