1999 DODGE NEON suspension

Do not attempt to use a different procedure from that
below for the removal and replacement of rear lower
control arm bushing.
(1) Remove the lower control arm assembly from
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required removal procedure.
(2) Position lower control arm in an arbor press
supported at rear bushing using Receiver Cup, Spe-
cial Tool 6756 (Fig. 85). Position Remover/Installer,
Special Tool 6758 on top of rear control arm bushing
(Fig. 85).
(3) Press isolator bushing out of the lower control
arm.
ASSEMBLY
(1) Install the rear bushing into the lower control
arm in the direction indicated in (Fig. 86).Rear
bushing must be positioned in lower control
arm with the void in the bushing pointing
toward the compression strut of the lower con-
trol arm as shown in (Fig. 86).
(2) Place lower control arm in an arbor press sup-
ported at rear bushing hole using Receiver Cup, Spe-
cial Tool 6756 (Fig. 87). Correctly position Remover/
Installer, Special Tool 6760 on top of rear control arm
bushing (Fig. 87).
(3) Press rear bushing into lower control arm,
until flange on bushing is flush with machined sur-
face of lower control arm (Fig. 88).
(4) Install the lower control arm assembly back on
the vehicle. See Lower Control Arm in the Removal
And Installation Section in this group of the service
manual for the required installation procedure.
Fig. 85 Special Tools Assembled For Removing
Rear Bushing
Fig. 86 Correct Installation Of Bushing In Lower
Control Arm
Fig. 87 Rear Bushing Installation
Fig. 88 Correctly Installed Rear Bushing
PLSUSPENSION 2 - 35
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

SPECIAL TOOLS
FRONT SUSPENSION
Socket/Holder Front Strut Nut L-4558A
Compressor Strut Coil Spring C-4838
Press Remover/Installer C-4212-F
Remover Lower Control Arm Small Bushing And
Ball Joint 6804
Installer Ball Joint 6758
Installer Lower Control Arm Small Bushing 6810
Adapter Ball Joint Remover/Installer C-4212-3
Receiver Ball Joint 6756
PLSUSPENSION 2 - 37

Remover/Installer Lower Control Arm Bushing
6644-2
Installer Ball Joint 6760
Remover Tie Rod End MB-990635
Splitter Bearing 1130
Remover Ball Joint MB-990799
Installer Bearing 5052
Installer Adapter C-4698-2
Remover Lower Ball Joint C-4150A
Installer Bearing Cup 6522
2 - 38 SUSPENSIONPL
SPECIAL TOOLS (Continued)

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 39
DESCRIPTION AND OPERATION
COIL SPRING........................... 41
COMPETITION PACKAGE SUSPENSION...... 41
KNUCKLE............................. 41
LATERAL LINKS AND TENSION STRUTS...... 41
REAR SUSPENSION..................... 39
STABILIZER BAR........................ 41
STRUT................................ 41
DIAGNOSIS AND TESTING
KNUCKLE............................. 42
LATERAL LINKS......................... 42
STABILIZER BAR AND BUSHINGS........... 43
STABILIZER BAR ATTACHING LINKS......... 43
STRUT INSPECTION (ON VEHICLE)......... 42
TENSION STRUT........................ 42
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT................ 43REMOVAL AND INSTALLATION
COIL SPRING........................... 44
KNUCKLE............................. 46
LATERAL LINKS......................... 48
STABILIZER BAR........................ 45
STRUT ASSEMBLY...................... 43
DISASSEMBLY AND ASSEMBLY
STABILIZER BAR BUSHINGS............... 53
STRUT ASSEMBLY...................... 50
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 53
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS...................... 54
SPECIAL TOOLS
REAR SUSPENSION..................... 54
GENERAL INFORMATION
GENERAL INFORMATION
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 with a new
component.
DESCRIPTION AND OPERATION
REAR SUSPENSION
The rear suspension system used on this vehicle is
a fully independent type rear suspension system (Fig.
1).A forged rear knuckle is bolted to each rear strut.
The movement of the rear knuckle is controlled lat-
erally using lateral links going from the front and
rear of the knuckle to the rear crossmember. Fore
and aft movement of the knuckle is controlled by a
tension strut.
The lateral links and tension strut have rubber iso-
lator bushings at each end. The lateral links are
attached to the rear crossmember and knuckle, using
a common bolt and nut assembly at each end. The
tension strut bolts to the bottom of the knuckle and
to a bracket attached to the floor pan of the vehicle.
The lateral links, tension strut and spindle are
normally replaced only when the part has been dam-
aged or when the vehicle has been involved in an
accident. If a suspension part has been damaged, be
sure to check the underbody dimensions of the car. If
the underbody dimensions are not correct, the frame
of the vehicle must be straightened, before replace-
ment suspension components are installed.
PLSUSPENSION 2 - 39

Fig. 1 Fully Independent Rear Suspension
2 - 40 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

COMPETITION PACKAGE SUSPENSION
On vehicles that are equipped with the optional
competition package, special rear struts are used.
The rear struts used on a vehicle equipped with
the competition package are adjustable. The adjust-
able struts use a unique strut shaft which has an
adjustment rod through the center of it (Fig. 2). The
adjustment rod is used to adjust the compression
dampening of the strut. By increasing the compres-
sion dampening of the strut, the jounce reaction of
the strut is slowed down. This slowing down of the
jounce reaction of the strut, stiffens the suspension
thus improving the handling of the vehicle.
The compression dampening of the strut is
adjusted using the adjustment knob (Fig. 3) which is
supplied with the vehicle at the time of purchase.
STRUT
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around the
struts. The coil springs are contained between theupper mount of the strut assembly and a lower
spring seat on the body of the strut assembly.
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 and prevailing torque
nuts. Rear Caster and camber on this vehicle is a
fixed setting (net build) and is not required to be
adjusted as a normal procedure when performing an
alignment on this vehicle.
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. During service
procedures when both rear coil springs are removed,
mark the coil springs to ensure installation of the
springs in their original position.If coil springs
require replacement, be sure the springs need-
ing replacement, are replaced with springs
meeting the correct load rating for the vehicle
and its specific options.
STABILIZER BAR
The stabilizer bar interconnects both rear strut
assemblies and is attached to the rear frame rails of
the vehicle.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle to stabilize body roll.
Attachment of the stabilizer bar to the rear frame
rails of the vehicle is through 2 rubber-isolator bush-
ings and bushing retainers. The stabilizer bar to
strut assembly attachment is done utilizing a rubber
isolated stabilizer bar attaching link. All parts of the
stabilizer bar are serviceable, and the stabilizer bar
to frame rail isolator bushings are split for easy
removal and installation. The split in the stabilizer
bar to crossmember bushing must be positioned
toward the rear of the vehicle, when the stabilizer
bar is installed on the vehicle.
KNUCKLE
A forged rear knuckle bolts to each rear strut
assembly. The movement of the rear knuckle is con-
trolled laterally using two lateral arms attached to
the knuckle. The outboard ends of the two lateral
arms are mounted forward and rearward of the spin-
dle centerline, and inboard ends are mounted to the
rear crossmember. Fore and aft movement of the
knuckle is controlled by using a tension strut.
LATERAL LINKS AND TENSION STRUTS
The lateral arms and tension strut have rubber
isolator bushings at each end. The lateral arms are
attached to the rear crossmember and knuckle, using
Fig. 2 Adjustable Front Strut
Fig. 3 Adjustable Strut Adjustment Knob
PLSUSPENSION 2 - 41
DESCRIPTION AND OPERATION (Continued)

a unique bolt and nut assembly at each end. The lat-
eral 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 2 flat washers. Each lateral arm
to rear crossmember attaching bolt uses 1 flat
washer and 1 adjustment cam to provide a means for
rear wheel Toe adjustment. The tension strut assem-
bly attaches to a bracket on the frame rail and to the
bottom of the knuckle.
Lateral arms, tension struts and knuckles are nor-
mally replaced only when the part has been damaged
or when the vehicle has been involved in an accident.
If a suspension part has been damaged, be sure to
check the underbody dimensions of the car. If under-
body dimensions of the vehicle are not correct, the
frame must be straightened before replacement sus-
pension components are installed.
DIAGNOSIS AND TESTING
STRUT INSPECTION (ON VEHICLE)
(1) Inspect for damaged or broken coil springs
(Fig. 4).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 4).
(3) Inspect for damaged lower spring isolator (Fig.
4).
(4) Lift dust boot and inspect strut assembly for
evidence of fluid running from the upper end of fluid
reservoir. (Actual leakage will be a stream of fluid
running down the side and dripping off lower end ofunit). A slight amount of seepage between the strut
rod and strut shaft seal is not unusual and does not
affect performance of the strut assembly (Fig. 5). Also
inspect jounce bumpers for signs of damage or dete-
rioration.
KNUCKLE
The rear knuckle is not a repairable component of
the rear suspension. If it is determined that the
knuckle is cracked, bent or broken when servicing
the vehicle, 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.
LATERAL LINKS
Inspect the lateral link isolator bushings and
sleeves for signs of damage or deterioration. If the
lateral link isolator bushings or sleeves are damaged
or are deteriorated, replacement of the lateral link
assembly will be required. The isolator bushings are
not serviceable as a separate component of the lat-
eral link assembly.
Inspect the lateral links for signs of contact with
the ground or road debris which has bent or caused
other damage to the lateral link assembly. If the lat-
eral link is bent or damaged, the lateral link will
require replacement.Do not attempt to repair or
straighten a lateral link.
TENSION STRUT
Inspect the tension strut bushings and retainers
for signs of deterioration or damage. If the tension
strut bushings are deteriorated or the retainers are
damaged, replacement of the tension strut bushings
and or the retainers will be required. The bushings
and retainers are serviceable as separate components
of the tension strut.
Fig. 4 On Vehicle Strut Assembly Inspection
Fig. 5 Strut Assembly Leakage Inspection
2 - 42 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)