1999 DODGE NEON differential

DIFFERENTIAL AND DRIVELINE
CONTENTS
page page
GENERAL INFORMATION
FRONT DRIVESHAFTS.................... 1
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS.................. 2
REMOVAL AND INSTALLATION
FRONT DRIVESHAFTS.................... 2
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION............... 7INNER TRIPOD JOINT SEAL BOOT.......... 9
OUTER C/V JOINT SEAL BOOT............ 13
SPECIFICATIONS
TORQUE.............................. 16
SPECIAL TOOLS
DRIVESHAFT........................... 16
GENERAL INFORMATION
FRONT DRIVESHAFTS
Vehicles equipped with either an automatic or
manual transmission use the unequal±length drive-
shaft system.
Vehicles equipped with automatic transaxles use a
solid short interconnecting shaft on the left side. The
right side of the vehicle uses a longer solid intercon-
necting shaft (Fig. 1).
Vehicles equipped with manual transaxles use a
larger diameter (32 mm) short interconnecting shaft
on the left side. The right side uses a longer inter-
connecting damper (Fig. 1).Driveshafts used on both the right and left sides of
the vehicle use a tuned rubber damper weight. The
damper weight applications vary by which side of the
vehicle the driveshaft is located on and the transmis-
sion application of the vehicle. When replacing a
driveshaft, be sure the replacement driveshaft has
the same damper weight as the original.
Both driveshaft assemblies use the same type of
inner and outer joints. The inner joint of both drive-
shaft assemblies is a tripod joint, and the outer joint
of both driveshaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (C/V) joint assemblies. The inner tripod joint
allows for the changes in driveshaft length through
Fig. 1 Unequal Length Driveshaft System
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the jounce and rebound travel of the front suspen-
sion.
On vehicles equipped with ABS brakes, the outer
C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.
The inner tripod joint of both driveshafts is splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle using
a snap ring located in the stub shaft of the tripod
joint. The outer C/V joint has a stub shaft that is
splined into the wheel hub and retained by a hub nut
using a nut lock and cotter pin.
NOTE: This vehicle does not use a rubber±lip bear-
ing seal as on previous front±wheel±drive cars to
prevent contamination of the front wheel bearing.
On these vehicles, the face of the outer C/V joint
fits deeply into the steering knuckle, using a close
outer C/V joint±to±steering knuckle fit. This design
deters direct water splash on bearing seal while
allowing any water that gets in, to run out the bot-
tom of the steering knuckle bearing bore. It is
important to thoroughly clean the outer C/V joint
and the wheel bearing area in the steering knuckle
before it is assembled after servicing.
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam-
age.
(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.
The right inner tripod joint seal boot is made of sili-
cone rubber; which will allow the weeping (sweating)
of the joint lubricant to pass through it while in oper-
ation.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions.
(1) Damaged outer C/V or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.
(2) Noise may also be caused by another compo-
nent of the vehicle coming in contact with the drive-
shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
(1) A torn seal boot on the inner or outer joint of
the driveshaft assembly.
(2) A loose or missing clamp on the inner or outer
joint of the driveshaft assembly.
(3) A damaged or worn driveshaft C/V joint.
SHUDDER OR VIBRATION DURING
ACCELERATION
(1) A worn or damaged driveshaft inner tripod
joint.
(2) A sticking tripod joint spider assembly (inner
tripod joint only).
(3) Improper wheel alignment. See Wheel Align-
ment in this group for alignment checking and set-
ting procedures and specifications.
VIBRATION AT HIGHWAY SPEEDS
(1) Foreign material (mud, etc.) packed on the
backside of the wheel(s).
(2) Out of balance front tires or wheels. See Group
22, Wheels And Tires for the required balancing pro-
cedure.
(3) Improper tire and/or wheel runout. See Group
22, Wheels And Tires for the required runout check-
ing procedure.
REMOVAL AND INSTALLATION
FRONT DRIVESHAFTS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the driveshaft
to prevent damage.
REMOVAL
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER±SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N´m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(1) Remove cotter pin, nut lock, and spring washer
(Fig. 2) from the end of the outer C/V joint stub axle.
(2) Loosen (but do not remove) stub axle±to±hub/
bearing retaining nut (Fig. 3). Loosen hub nut while
3 - 2 DIFFERENTIAL AND DRIVELINEPL
GENERAL INFORMATION (Continued)

vehicle is on the floor with the brakes applied. The
front hub and driveshaft are splined together and
retained by the hub nut.
(3) Raise vehicle on jack stands or centered on a
frame contact±type hoist. See Hoisting in the Lubri-
cation and Maintenance section for required lifting
procedure to be used for this vehicle.
(4) Remove front tire and wheel assembly from the
hub.
(5) Remove front disc brake caliper assembly to
steering knuckle bolts (Fig. 4).
(6) Remove disc brake caliper assembly from steer-
ing knuckle. Caliper is removed by first lifting bot-
tom of caliper away from steering knuckle, and then
removing top of caliper out from under steering
knuckle.
(7) Support brake caliper/adapter assembly using a
wire hook,not by the brake flex hose(Fig. 5).
(8) Remove braking disc from front hub.
(9) Remove nut attaching outer tie rod end to
steering knuckle.Nut is to be removed from tie
rod end using the following procedure: Hold tierod end stud with a 11/32 socket while loosen-
ing and removing nut.
(10) Remove the tie rod end stud from steering
knuckle arm using Special Tool MB-991113 (Fig. 6).
Fig. 2 Cotter Pin, Nut Lock and Spring Washer
Fig. 3 Loosening Front Hub Retaining Nut
Fig. 4 Front Disc Brake Caliper Assembly Bolts
Fig. 5 Supporting Brake Caliper
Fig. 6 Tie Rod End Removal From Steering Knuckle
PLDIFFERENTIAL AND DRIVELINE 3 - 3
REMOVAL AND INSTALLATION (Continued)

(11) Remove nut and bolt (Fig. 7) retaining ball
joint stud into steering knuckle.
NOTE: Use caution when separating ball joint stud
from steering knuckle, so ball joint seal does not
get damaged.
(12) Separate ball joint stud from steering knuckle
by prying down on lower control arm (Fig. 8).
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.
(13) Remove the hub and bearing to stub axle
retaining nut.
(14) Install Puller, Special Tool 6790 on hub and
bearing assembly (Fig. 9), using wheel lug nuts to
secure it in place.(15) Install a wheel lug nut on wheel stud to pro-
tect the threads on the stud. Install a flat blade pry
tool to keep hub from turning. Using Puller, force the
outer stub axle from the hub and bearing asssembly
(Fig. 10).
(16) Pull steering knuckle assembly out and away
from outer C/V joint of the driveshaft assembly (Fig.
11).
(17) Support outer end of the driveshaft assembly.
NOTE: Removal of the inner tripod joints is made
easier if you apply outward pressure on the joint as
you strike the punch with a hammer.
(18) Remove the inner tripod joints from the side
gears of the transaxle using a punch to dislodge the
inner tripod joint retaining ring from the transaxle
side gear. If removing the right side inner tripod
joint, position the punch against the inner tripod
joint (Fig. 12). Strike the punch sharply with a ham-
mer to dislodge the right inner joint from the side
gear. If removing the left side inner tripod joint, posi-
Fig. 7 Removing Steering Knuckle Clamp Bolt
Fig. 8 Separate Ball Joint Stud from Steering
Knuckle
Fig. 9 Puller Installed On Hub/Bearing Assembly
Fig. 10 Removing Stub Axle From Hub/Bearing
3 - 4 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

tion the punch in the groove of the inner tripod joint
(Fig. 13). Strike the punch sharply with a hammer to
dislodge the left inner tripod joint from the side gear.
(19) Hold inner tripod joint and interconnecting
shaft of driveshaft assembly (Fig. 14). Remove inner
tripod joint from transaxle by pulling it straight out
of transaxle side gear and transaxle oil seal.When
removing tripod joint, do not let spline or snap
ring drag across sealing lip of the transaxle to
tripod joint oil seal.
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER±SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N´m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
INSTALLATION
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding driveshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into tran-
saxle side gear as far as possible by hand.
(3) Carefully align tripod joint with transaxle side
gears. Then grasp driveshaft interconnecting shaft
and push tripod joint into transaxle side gear until
fully seated.Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.
Fig. 11 Steering Knuckle Separation from Driveshaft
Fig. 12 Disengaging Right Inner Tripod Joint from
Transaxle
Fig. 13 Disengaging Left Inner Tripod Joint from
Transaxle
Fig. 14 Tripod Joint Removal from Transaxle
PLDIFFERENTIAL AND DRIVELINE 3 - 5
REMOVAL AND INSTALLATION (Continued)

(4) Clean all debris and moisture out of steering
knuckle (Fig. 15).
(5) Ensure that front of outer C/V joint, which fits
into steering knuckle (Fig. 16), is free of debris and
moisture before assembling into steering knuckle.
(6) Slide driveshaft back into front hub. Install
steering knuckle onto the ball joint stud (Fig. 17).
(7) Install aNEWsteering knuckle to ball joint
stud bolt and nut (Fig. 18). Tighten the nut and bolt
to 95 N´m (70 ft. lbs.).
(8) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle nut onto stud of tie
rod end. While holding stud of tie rod end stationary,
tighten tie rod end to steering knuckle nut. Then,
using a crowfoot and 11/32 socket, tighten tie rod end
nut to 61 N´m (45 ft. lbs.).
(9) Install braking disc back on hub and bearing
assembly.
(10) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding top ofcaliper under top abutment on steering knuckle.
Then installing bottom of caliper against bottom
abutment of steering knuckle.
(11) Install caliper assembly to steering knuckle
bolts (Fig. 19). Tighten to 31 N´m (23 ft. lbs.).
(12) Clean all foreign matter from threads of outer
C/V joint stub axle. Install washer and hub nut onto
the threads of the stub axle and tighten nut.
(13) Install spring washer, nut lock, and cotter pin
on outer C/V joint stub axle (Fig. 20).
(14) With vehicle brakes applied to keep axle shaft
from turning, tighten hub nut to 203 N´m (150 ft.
lbs.).
(15) Install front wheel and tire assembly. Install
front wheel lug nuts and tighten to 135 N´m (100 ft.
lbs.).
(16) Check for correct fluid level in transaxle
assembly. Refer to Group 21 Transaxle, for the cor-
Fig. 15 Steering Knuckle to C/V Joint Sealing Area
Fig. 16 Outer C/V Joint Inspection
Fig. 17 Driveshaft Installation Into Hub And Steering
Knuckle
Fig. 18 Tighten Steering Knuckle Clamp Bolt
3 - 6 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (Continued)

rect fluid level checking procedure for the type of
transaxle being checked.
(17) Lower vehicle.
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION
NOTE: The only service that is to be performed on
the driveshaft assemblies is the replacement of the
driveshaft seal boots.
If any failure of internal driveshaft components is
diagnosed during a vehicle road test or disassembly
of the driveshaft, the driveshaft will need to be
replaced as an assembly.
NOTE: Lubricant requirements and quantities are
different for inner joints than for outer joints. Use
only the recommended lubricants in the required
quantities when servicing driveshaft assemblies.
See (Fig. 21) for the exploded view of the front
driveshaft components.
Fig. 19 Front Disc Brake Caliper Assembly Bolts
Fig. 20 Spring Washer, Nut Lock And Cotter Pin
Installation
PLDIFFERENTIAL AND DRIVELINE 3 - 7
REMOVAL AND INSTALLATION (Continued)

Fig. 21 Driveshaft Assembly Components (Exploded View)
3 - 8 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)