1999 DODGE NEON Service Repair Manual

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)

Inspect the tension strut for signs of contact with
the ground or road debris which 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.
STABILIZER BAR AND BUSHINGS
Inspect the stabilizer bar for damage or bending.
Inspect for broken or distorted stabilizer bar bush-
ings, bushing retainers, and worn or damaged stabi-
lizer bar to strut attaching links. If stabiizer bar to
rear frame rail bushing replacement is required,
bushings can be removed from sway bar by opening
slit and peeling bushing off sway bar.
STABILIZER BAR ATTACHING LINKS
Inspect the bushings and sleeves in the stabilizer
bar attaching links for damage or deterioration.
Inspect the stabilizer bar attaching link to ensure it
is not bent or broken. If any of these conditions are
present when inspecting the attaching links, replace-
ment of the attaching link is required.
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT
Refer to Front And Rear Wheel Toe Setting Proce-
dures in the Wheel Alignment Check And Adjustment
section in this group of the service manual for the
required rear wheel Toe setting procedure.
REMOVAL AND INSTALLATION
STRUT ASSEMBLY
REMOVE
(1) Raise vehicle on jackstands 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.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) Remove hydraulic flex hose bracket, from
bracket on rear strut assembly (Fig. 6). If vehicle is
equipped with Anti-Lock brakes, the wheel speed
sensor cable routing clip is also attached to the strut
assembly bracket.
(4) Support rear knuckle, suspension and brake
components of vehicle before removing clevis bracket
to knuckle attaching bolts.Do not let weight of
rear knuckle and assembled components hang
unsupported when strut is removed.CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
removal. Remove nuts while holding bolts station-
ary in knuckle.
(5) Remove the 2 clevis bracket bolts (Fig. 7)
attaching strut assembly to rear knuckle.
(6) Lower vehicle. Access to rear upper strut
mount to strut tower attaching bolts, is through the
trunk of the vehicle.
Fig. 6 Hydraulic Flex Hose Bracket Attachment To
Strut
Fig. 7 Knuckle To Clevis Bracket Bolts
PLSUSPENSION 2 - 43
DIAGNOSIS AND TESTING (Continued)

(7) Remove carpet (if required) from top of strut
tower. Then remove rubber dust shield (Fig. 8) from
top of strut tower, this will allow easier access to
upper strut mount attaching nuts.
(8) Loosen but do not remove the 4 upper strut
mount to strut tower attaching nuts (Fig. 9). Then
while supporting the strut assembly fully remove the
4 strut mount attaching nuts.
(9) Remove strut assembly from knuckle, by slid-
ing knuckle out of clevis bracket on strut assembly.
Then remove strut assembly from vehicle.
INSTALL
(1) Position strut assembly back into vehicle with
the 4 studs on strut mount assembly through holes
in strut tower of vehicle. Install the 4 strut mount to
body attaching nuts (Fig. 9) onto mount studs.
Torque the 4 strut mount to body attaching nuts to
34 N´m (300 in. lbs).(2) Install dust shield into hole on top of strut
tower (Fig. 8). Install carpeting back on top of rear
strut tower.
(3) Raise vehicle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
installation. Install and torque nuts while holding
bolts stationary in knuckle.
(4) Install knuckle assembly into clevis bracket on
strut assembly. Install the 2 clevis bracket to knuckle
assembly attaching bolts and nuts (Fig. 7). Torque
both clevis bracket to knuckle assembly attaching
nuts to 95 N´m (70 ft. lbs.).
(5) Install hydraulic flex hose bracket, on strut
assembly bracket (Fig. 6). Install and securely
tighten bolt attaching hose bracket to strut bracket.
If vehicle is equipped with Anti-Lock brakes, the
wheel speed sensor cable routing clip is also attached
to the strut assembly bracket.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat tightening sequence to full speci-
fied torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
(8) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
COIL SPRING
Coil springs are rated separately for each side of
vehicle depending on optional equipment and type of
service. During service procedures where both
springs are removed, mark springs (Chalk, Tape,
etc.) (Fig. 10) to ensure installation in original posi-
tion. If the coils springs require replacement.Be
sure that the springs needing replacement, are
replaced with springs meeting the correct load
and spring rate for the vehicle.
NOTE: During service procedures requiring
removal or installation of a coil spring with Spring
Compressor, Special Tool C-4838. It is required that
the first full top and bottom coil of the coil spring
be captured by the jaws of spring compressor (Fig.
10).
Replacement of the coil spring requires removal of
the strut assembly from the vehicle, and the disas-
sembly of the strut. Refer to strut assembly in the
removal and installation section in this group of the
service manual for the required removal and replace-
ment procedure for the strut assembly. Then refer to
Fig. 8 Dust Shield Removal From Strut Tower
Fig. 9 Strut Mount Attaching Nuts
2 - 44 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

strut assembly in the disassembly and assembly sec-
tion in this group of the service manual for the
required procedure to disassemble and assemble the
strut assembly for the removal of the coil spring.
STABILIZER BAR
REMOVE
(1) Raise vehicle on jackstands 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.
(2) Remove both rear wheel and tire assemblies
from the vehicle.
(3) Remove rear stabilizer bar from the 2 stabilizer
bar to strut attaching links (Fig. 11).
(4) Rotate stabilizer bar down slightly to clear
attaching links.
(5) Remove the 2 stabilizer bar to rear frame rail
retainers (Fig. 12).(6) Remove stabilizer bar from vehicle.
STABILIZER BAR AND BUSHING INSPECTION
Inspect for broken or distorted retainers and bush-
ings. If bushing replacement is required, bushing can
be removed by opening slit in bushing and removing
bushing from around stabilizer bar. When bushings
are installed on stabilizer bar, bushings must be
installed with slit positioned on stabilizer bar so slit
will face rear of vehicle when stabilizer bar is
installed (Fig. 13).
INSTALL
(1) Install stabilizer bar and isolator bushings
back into the vehicle as an assembly. Position stabi-
lizer bar so it is centered in the vehicle and does not
contact other suspension components or vehicle body.
(2) Install the 2 stabilizer bar to frame rail retain-
ers into frame rail and loosely install both retainer
attaching bolts (Fig. 12).
(3) Position both stabilizer bar to strut assembly
attaching links on stabilizer bar. Install and securely
tighten the stabilizer bar attaching link to stabilizer
bar attaching nuts (Fig. 11).
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
Fig. 10 Identifying Coil Springs
Fig. 11 Sway Bar To Strut Attaching Link
Fig. 12 Sway Bar To Frame Rail Retainers
Fig. 13 Bushings Correctly Installed On Stabilizer
Bar
PLSUSPENSION 2 - 45
REMOVAL AND INSTALLATION (Continued)