1999 DODGE NEON Service Repair Manual

sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 129 N´m (95 ft. lbs.).
(5) Lower the vehicle to the ground.
(6) With suspension supporting the full weight of
the vehicle, securely tighten the stabilizer bar
retainer to frame rail attaching bolts (Fig. 11).
KNUCKLE
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.
(3) If vehicle is equipped with rear disc brakes,
remove the rear caliper from the adapter. Refer to
Rear Disk Brakes in Group 5 Brakes of this Service
manual for required caliper removal procedure. After
removing the caliper, store the caliper by hanging it
from frame of the vehicle (Fig. 14). Do not let weight
of rear caliper hang from flexible brake hose.
(4) If vehicle is equipped with rear disc brakes,
remove rotor from hub. If vehicle is equipped with
rear drum brakes, remove brake drum from hub.
(5) If vehicle is equipped with ABS brakes, remove
wheel speed sensor from rear disc brake adapter
(Fig. 15).
(6) Remove rear hub/bearing retaining nut (Fig.
16). Then remove the hub/bearing from the knuckle.(7) If vehicle is equipped with rear drum brakes
remove the 4 bolts (Fig. 17) attaching rear brake sup-
port plate to knuckle. Then remove brake support
plate, brake shoes and wheel cylinder as an assembly
from rear knuckle (Fig. 17).It is not necessary to
remove brake flex hose from wheel cylinder
when removing support plate.Brake support
plate when removed, must be supported in same
manner as caliper assembly.
(8) On vehicles equipped with rear disc brakes,
remove the 4 bolts attaching disc brake adapter to
rear knuckle (Fig. 18). Then remove the adapter,
rotor shield, park brake shoes and park brake cable
as an assembly from knuckle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
removal. Loosen and remove nuts while holding
bolts stationary in knuckle.
Fig. 14 Storing Rear Caliper
Fig. 15 Speed Sensor Head Attachment To Disc
Brake Adapter
Fig. 16 Hub/ Bearing Retaining Nut
2 - 46 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(9) Loosen but do not remove at this time, the 2
strut assembly to knuckle attaching bolts (Fig. 19).
Then remove the lateral links to knuckle attaching
bolt (Fig. 19).
(10) Hold tension strut from turning by using a
large adjustable wrench on flat of tension strut (Fig.
20) and remove tension strut nut. Then remove nut,
tension strut retainer and rear tension strut bushing
from tension strut at rear knuckle (Fig. 20).
(11) Remove both rear knuckle to strut assembly
clevis bracket attaching bolts (Fig. 19). If vehicle is
equipped with a rear sway bar also remove the sway
bar link to strut mounting bracket (Fig. 19).
(12) Remove knuckle assembly from strut, by slid-
ing knuckle straight out of clevis bracket on strut
assembly. Then remove knuckle from tension strut.
INSTALL
(1) Insert tension strut, tension strut bushing and
tension strut retainer into knuckle. Then install
knuckle into clevis bracket on rear strut assembly.Be sure stepped area of bushing is squarely
seated into hole in knuckle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
installation. Tighten and torque nuts while holding
bolts stationary in knuckle.
(2) Install the 2 strut assembly clevis bracket to
knuckle attaching bolts and nuts (Fig. 19). Torque
the attaching bolts to 95 N´m (70 ft. lbs.).
(3) Install the lateral arms to knuckle attaching
bolt, washers and nut as shown in (Fig. 19).Do not
tighten the lateral link bolt at this time. The
vehicle must be at curb height when tightening
the lateral link bolts.
Fig. 17 Drum Brake Support Plate Mounting Bolts
Fig. 18 Disc Brake Adapter Mounting
Fig. 19 Knuckle To Strut And Lateral Arm Mounting
Bolts
Fig. 20 Tension Strut To Rear Knuckle Attachment
PLSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

(4) Install tension strut bushing, tension strut
retainer and nut on tension strut (Fig. 21).When
installing tension strut retainers, the retainers
must be installed on tension strut, with cupped
side of retainer facing away from bushing and
knuckle (Fig. 21).
(5) Position a large adjustable wrench on flat of
tension strut to keep it from turning, (Fig. 22) and
then torque tension strut nut to 95 N´m (70 ft. lbs.).
(6) On vehicles equipped with rear drum brakes,
install rear brake support plate assembly onto the
knuckle (Fig. 17). Install the 4 bolts (Fig. 17) attach-
ing rear brake support plate to rear knuckle. Torque
attaching bolts to 68 N´m (50 ft. lbs.).
(7) On vehicles equipped with rear disc brakes,
install the disc brake adapter on knuckle (Fig. 18)
Install the 4 bolts attaching the disc brake adapter to
knuckle (Fig. 18). Torque attaching bolts to 68 N´m
(50 ft. lbs.).(8) If vehicle is equipped with ABS brakes, install
speed sensor head into rear brake support plate or
disc brake adapter (Fig. 15). Tighten wheel speed
sensor mounting bolt to a torque of 7 N´m (60 in.
lbs.).
CAUTION: The hub/bearing retaining nut must be
tightened to but must not exceed its required
torque specification. The proper torque specifica-
tion of the retaining nut is critical to the life of the
hub bearing.
(9) Install rear hub and bearing assembly on
knuckle. Install hub and bearing assembly retaining
nut (Fig. 16), and torque to 217 N´m (160 ft. lbs).
(10) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. If vehicle is
equipped with rear drum brakes, install the brake
drum on hub.
(11) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. Carefully install
rear brake caliper over braking disc and install on
adapter. Tighten the caliper assembly to adapter
mounting bolts to 22 N´m (192 in. lbs.). Refer to Rear
Disc Brakes in Group 5 Brakes in this service man-
ual for required caliper installation procedure.
(12) 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 the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(13) Lower vehicle.
(14) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(15) 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.
LATERAL LINKS
The rear suspension lateral links (Fig. 23) are only
serviced as complete assemblies. The isolator bush-
ings used in the lateral links are not serviced as sep-
arate components. The rear lateral link assemblies
are unique, having different size bushings to accom-
modate the rear Toe adjustment cams. The rearward
lateral links, must be installed with small bushing
sleeve at knuckle and large bushing sleeve at rear
crossmember. This is required to accommodate the
rear Toe adjustment cam.
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 21 Tension Strut Bushings Installed On Tension
Strut
Fig. 22 Torquing Tension Strut Nut
2 - 48 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

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 side of the vehicle requiring lateral link removal.
(3) Remove the nut, bolt and washers attaching
the lateral links to the knuckle (Fig. 24).
(4) Remove nut, bolt, washer and Toe adjustment
cam, attaching lateral links requiring removal, from
rear crossmember (Fig. 25). Then remove lateral
links from vehicle.
INSTALL
Rear lateral links when being installed, must be
specifically positioned and orientated on the vehicle.The lateral link having same size bushing sleeves,
must be mounted to the crossmember and knuckle
toward front of vehicle. The lateral link with differ-
ent size bushing sleeves, must be mounted to the
crossmember and knuckle toward rear of vehicle. The
lateral link with small and large bushing sleeves,
must be installed with small bushing sleeve at
knuckle and large bushing sleeve at rear crossmem-
ber. This is required to accommodate the rear Toe
adjustment cam at rear crossmember.
The lateral link mounting bolts are different
lengths, and need to be installed in specific locations
and direction on vehicle.The lateral link mount-
ing bolt at knuckle MUST be installed, with
head of bolt facing front of vehicle. The lateral
Fig. 23 Rear Suspension Lateral Links
Fig. 24 Lateral Link Attachment To Knuckle
Fig. 25 Lateral Link Attachment To Crossmember
PLSUSPENSION 2 - 49
REMOVAL AND INSTALLATION (Continued)

link mounting bolt at crossmember MUST be
installed, with head of bolt facing rear of vehi-
cle. The long attaching bolt must be used at
rear crossmember and short bolt used at
knuckle.
(1) Install washer on short lateral link attaching
bolt. Then install short lateral link attaching bolt,
into lateral link having the same size bushing
sleeves. Then install lateral link, bolt and washer
onto knuckle as an assembly, with head of bolt facing
to front of vehicle (Fig. 24).
(2) Install lateral link with small and large bush-
ing sleeve, on lateral link attaching bolt in rear
knuckle (Fig. 24).Small bushing sleeve must be
installed on bolt in rear knuckle with large
bushing sleeve at crossmember of vehicle.
(3) Install washer and nut onto lateral link attach-
ing bolt at rear knuckle (Fig. 24).Do not tighten
the lateral link to rear knuckle attaching bolt
at this time.
(4) Install Toe adjustment cam on long lateral link
attaching bolt. Install long lateral link attaching bolt
and adjustment cam, into lateral link toward rear of
vehicle, having the large bushing sleeve. Then pass
lateral link attaching bolt into rear crossmember
(Fig. 26).Head of long lateral link to crossmem-
ber attaching bolt must face to rear of vehicle
when installed.
(5) Position forward rear lateral link against rear
crossmember (Fig. 26). Then pass the lateral link
attaching bolt through front lateral link bushing
sleeve.
(6) Install washer and nut onto lateral link attach-
ing bolt at rear crossmember (Fig. 26).Do not
tighten the lateral link to rear crossmember
attaching bolt at this time.
(7) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(8) Lower vehicle to the ground.
(9) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(10) 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.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY
DISASSEMBLY
The rear strut unit is not serviced and must be
replaced as an assembly if found to be defective. The
strut is available with 2 calibrations, be sure strut is
replaced with an assembly of the same calibration.
The components of the strut assembly listed below
are replaceable if found to be defective.
²Coil spring (Coil springs come in a standard rate
of 120 lb./in. be sure spring is replaced with a spring
of the same rate.)
²Dust shield
²Mount assembly
²Jounce Bumper
²Lower Spring Isolator
²Shaft Nut
(1) Remove strut assembly requiring service from
the vehicle. Refer to Strut Assembly Removal in Ser-
vicing Rear Struts, in this section of the service man-
ual.
(2) Position strut assembly in a vise (Fig. 27).
Using paint or equivalent, mark the strut unit, lower
spring isolator, spring and upper strut mount for
indexing of the parts at assembly.
(3) Position Spring Compressors, Special Tool
C-4838 on the strut assembly spring (Fig. 28). Com-
press coil spring until all load is removed from upper
strut mount assembly.
(4) Install Strut Rod Socket, Special Tool, L-4558A
or L-4558 on strut shaft nut (Fig. 29). Inserted a 10
mm socket through special tool and onto end of strut
shaft (Fig. 29) to keep strut shaft from turning.
Remove strut shaft nut from strut shaft.
(5) Remove washer (Fig. 30) between strut shaft
nut and upper strut mount and isolator.
(6) Remove upper strut mount assembly from strut
shaft and spring (Fig. 31).
Fig. 26 Lateral Link Attachment To Crossmember
2 - 50 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(7) Remove the washer from strut shaft, that is
between the strut upper mount assembly and dust
shield (Fig. 32).
Fig. 27 Strut Assembly Mounted In Vise
Fig. 28 Compressing Strut Assembly Coil Spring
Fig. 29 Removing/Installing Strut Shaft Nut
Fig. 30 Strut Mount Washer
Fig. 31 Upper Strut Mount
Fig. 32 Washer
PLSUSPENSION 2 - 51
DISASSEMBLY AND ASSEMBLY (Continued)

(8) Remove the coil spring and spring compressor
as an assembly from the strut (Fig. 33).
(9) Remove the dust shield from the strut assem-
bly (Fig. 34).
(10) Remove the jounce bumper (Fig. 35) from the
shaft of the strut assembly.
(11) Remove the coil spring lower isolator from the
strut assembly spring seat (Fig. 36).
(12) Inspect all disassembled components for signs
of abnormal wear or failure replacing any compo-
nents as required. Inspect strut unit for signs of
abnormal oil leakage and for loss of gas charge. To
check for loss of gas charge in strut unit. Push strut
shaft into body of strut and release, strut shaft
should return to its fully extended position. If strut
shaft does not return to its fully extended position
replace strut unit.
ASSEMBLY
(1) Install the original or a new isolator on lower
spring seat of strut (Fig. 36).(2) Install jounce bumper on strut shaft (Fig. 35).
(3) Install the dust shield on the strut assembly
(Fig. 34).
(4) Lower the coil spring onto the strut unit (Fig.
33). Position end of coil spring against edge of spring
isolator on lower spring seat of strut assembly.
(5) Install washer on strut shaft with raised edge
of washer facing upward (Fig. 32).
(6) Install the strut assembly upper mount onto
the strut shaft (Fig. 31).
(7) Install the washer on the strut assembly upper
mount (Fig. 30). Washer must be installed with the
raised edge of the washer facing down.
(8) Install the upper strut mount to strut shaft
retaining nut.
(9) Using Strut Rod Socket, Special Tool, L-4558A
and a 10 mm socket (Fig. 29) to keep strut shaft from
turning, torque the strut shaft nut to 61 N´m (45 ft.
lbs.).
(10) Equally loosen the Spring Compressors, Spe-
cial Tool C-4838 until spring is seated on upper strut
Fig. 33 Coil Spring And Compressor
Fig. 34 Dust Shield
Fig. 35 Jounce Bumper
Fig. 36 Coil Spring Lower Isolator
2 - 52 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

mount and all tension is relieved from the spring
compressors.
(11) Install the strut assembly back into the vehi-
cle. Refer to Strut Assembly Removal in Servicing
Rear Struts in this section of the service manual.
(12) Check and reset rear wheel TOE to specifica-
tions if required.
STABILIZER BAR BUSHINGS
(1) If stabilizer bar to frame rail bushings require
replacement at time of inspection, install new bush-
ings before installing stabilizer bar. Bushings are
replaced by opening slit on bushings and peeling
them off stabilizer bar. Install new bushings on sta-
bilizer bar, by spreading bushing at slit and forcing
them on stabilizer bar.Bushings must be installed
on stabilizer bar with slit in bushing facing
rear of vehicle when stabilizer bar is installed
(Fig. 37).
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION PACKAGE
SUSPENSION
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. 38).
The compression dampening of the strut is
adjusted using the adjustment knob (Fig. 39) which
is supplied with the vehicle at the time of purchase.
The adjustment is done by inserting the flat on the
end of the adjustment rod into the grove on the
adjustment knob (Fig. 40). The compression dampen-
ing is increased by rotating the adjustment knob
(Fig. 39) in a counterclockwise direction and
decreased by rotating the adjustment knob in a clock-
wise direction.
Fig. 37 Correct Stabilizer Bushing Installation
Fig. 38 Adjustable Rear Strut
Fig. 39 Adjustable Strut Adjustment Knob
Fig. 40 Adjustment Knob Installation
PLSUSPENSION 2 - 53
DISASSEMBLY AND ASSEMBLY (Continued)