1999 DODGE NEON steering wheel adjustment

SUSPENSION
CONTENTS
page page
FRONT SUSPENSION..................... 10
REAR SUSPENSION...................... 39WHEEL ALIGNMENT....................... 1
WHEEL ALIGNMENT
INDEX
page page
DESCRIPTION AND OPERATION
COMPETITION PACKAGE ALIGNMENT........ 2
WHEEL ALIGNMENT GENERAL
INFORMATION......................... 1
DIAGNOSIS AND TESTING
PRE-ALIGNMENT VEHICLE INSPECTION...... 5
SUSPENSION AND STEERING DIAGNOSIS.... 3SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT PROCEDURE.............. 5
SPECIFICATIONS
VEHICLE ALIGNMENT SPECIFICATIONS AT
CURB HEIGHT......................... 9
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT GENERAL INFORMATION
Proper vehicle wheel alignment is the proper
adjustment of all interrelated front and rear suspen-
sion angles (Fig. 1). These angles are what affects
the handling and steering of the vehicle when it is in
motion.
The method of checking a vehicle's front and rear
wheel alignment will vary depending on the type and
manufacturer of the equipment being used. Instruc-
tions furnished by the manufacturer of the equip-
ment being used should always be followed to ensure
accuracy of the alignment, except alignment specifi-
cations recommended by Chrysler Corporation
MUST ALWAYSbe used.
CAUTION: Do not attempt to modify any suspen-
sion or steering components by heating or bending
of the component.Wheel alignment adjustments should be made in
the following sequence, to ensure that an accurate
alignment is performed.
(1) Rear Wheel Toe Adjustment within specifica-
tions for both total toe and thrust angle.
(2) Front Wheel Toe Adjustment within specifica-
tions for total toe.
(3)To eis measured in degrees or inches and is
the distance that the front edges of the tires are
closer (or farther apart) than the rear edges (Fig. 1).
See Front Wheel Drive Specifications for correct front
and rear wheel Toe specifications.
(4)Thrust Angleis defined as the average of the
Toe settings on each rear wheel. If this measurement
is out of specification, re-adjust rear wheel Toe so
that each wheel has 1/2 of the total Toe measure-
ment. When re-adjusting, do not exceed the total Toe
specification.
PLSUSPENSION 2 - 1

COMPETITION PACKAGE ALIGNMENT
If a vehicle is equipped with the optional competi-
tion package, (S/C ACR) the front wheel camber is
adjustable.
These vehicles come equipped with a special front
strut (Fig. 2). The clevis bracket (Fig. 2) used on this
strut has a slotted hole for the bottom mounting bolt.
Also, the bottom mounting bolt used on this strut has
an eccentric at the head of the bolt (Fig. 2). When the
bolt is rotated, the eccentric pushes against the
flange (Fig. 2) and a raised tab on the clevis bracket.
This forces the steering knuckle to change position
relative to strut, thus changing the camber setting of
the front wheel.
The allowable adjustment range of the front cam-
ber is from ±1.00 degrees to + 0.25 degrees.
NOTE: This vehicle is delivered from the dealer
with the camber set to the preferred specification.
The camber is only to be set to a specification that
is not the preferred camber setting when the vehi-
cle is going to be used in a competitive driving
event. The front camber must always be set back to
the preferred camber specification when the vehicle
is to be driven on the street under normal driving
conditions.
Fig. 1 Alignment Camber/Toe
Fig. 2 Strut To Steering Knuckle Attachment With
Competitive Package.
2 - 2 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Road Wander 1. Incorrect Tire Pressure 1. Inflate Tires To Rcommended
Pressure
2. Incorrect Front Or Rear Wheel
To e2. Check And Reset Front Wheel
To e
3. Worn Wheel Bearings 3. Replace Wheel Bearing
4. Worn Control Arm Bushings 4. Replace Control Arm Bushing
5. Excessive Friction In Steering
Gear5. Replace Steering Gear
6. Excessive Friction In Steering
Shaft Coupling6. Replace Steering Coupler
7. Excessive Friction In Strut Upper
Bearing7. Replace Strut Bearing
Lateral Pull 1. Unequal Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Radial Tire Lead 2. Perform Lead Correction
Procedure
3. Incorrect Front Wheel Camber 3. Check And Reset Front Wheel
Camber
4. Power Steering Gear Imbalance 4. Replace Power Steering Gear
5. Wheel Braking 5. Correct Braking Condition
Causing Lateral Pull
Excessive Steering Free Play 1. Incorrect Steering Gear
Adjustment1. Adjust Or Replace Steering Gear
2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends
3. Loose Steering Gear Mounting
Bolts3. Tighten Steering Gear Bolts To
The Specified Torque
4. Loose Or Worn Steering Shaft
Coupler5. Replace Steering Shaft Coupler
Excessive Steering Effort 1. Low Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Lack Of Lubricant In Steering
Gear2. Replace Steering Gear
3. Low Power Steering Fluid Level 3. Fill Power Steering Fluid
Reservoir To Correct Level
4. Loose Power Steering Pump Belt 4. Correctly Adjust Power Steering
Pump Drive Belt
5. Lack Of Lubricant In Steering Ball
Joints5. Lubricate Or Replace Steering
Ball Joints
6. Steering Gear Malfunction 6. Replace Steering Gear
7. Lack Of Lubricant In Steering
Coupler7. Replace Steering Coupler
2 - 4 SUSPENSIONPL
DIAGNOSIS AND TESTING (Continued)

PRE-ALIGNMENT VEHICLE INSPECTION
CAUTION: If the front suspension crossmember
shows any sign of impact damage, the steering col-
umn to steering gear coupling must be inspected.
Refer to Group 19 Steering in this service manual
for the inspection procedure.
Before any attempt is made to change or correct
the wheel alignment factors, the following inspection
and necessary corrections must be made on those
parts which influence the steering of the vehicle.
(1) Be sure the fuel tank is full when the wheel
alignment specifications are checked and or adjusted.
A full tank of fuel weighs approximately 75 pounds,
if the fuel tank is not full this reduction in weight
will affect the curb height of the vehicle and the
alignment specifications.
(2) Alignment specifications of a vehicle can be the
most accurately checked and set when the passenger
compartment and trunk of the vehicle are vacant
with the exception of the spare tire. People, luggage,
and any other appreciable weight will adversely
affect the checking and setting of the camber specifi-
cation.
(3) Check and if required, inflate all of the tires to
the recommended air pressure. All tires must be of
the same size and in good condition and have approx-
imately the same tread wear.Note the type of
tread wear on the tire, this will aid in diagnos-
ing problems. Refer to Group 22 Tires And
Wheels in this service manual for the tire wear
diagnosis.
(4) Check the front tire and wheel assemblies for
radial runout.
(5) Before beginning the alignment process,
inspect all suspension component fasteners for loose-
ness and/or loss of specified torque.
(6) Inspect the lower front ball joints and all steer-
ing linkage for looseness and any signs of wear and
or damage.
(7) Inspect the tie rod ends for looseness and any
signs of wear and or damage.
(8) Inspect the rubber bushings on all suspension
components for signs of wear or deterioration. If any
bushings show signs of wear or deterioration they
should be replaced prior to aligning the vehicle.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER CAMBER
Front and rear Caster and Camber settings on this
vehicle are determined at the time the vehicle isdesigned, by the location of the vehicle's suspension
components. This is called a Net Build vehicle and
results in no required adjustment of Caster and
Camber after vehicle is built or when servicing the
suspension components. Thus Caster and Camber are
not normally considered an adjustable specification
when performing an alignment on this vehicle.
Though Caster and Camber are not adjustable they
must be checked to ensure they meet vehicle specifi-
cations.
If front and or rear camber is found not to meet
the vehicle alignment specifications, it can be
adjusted using a Mopar Service Kit developed to
allow for camber adjustment. If a vehicle's front or
rear camber is found to be outside the specifications,
the vehicles suspension components should be
inspected for any signs of damage on bending.This
must be done before using the Mopar Service
Kit for setting camber to meet required specifi-
cation.
If a vehicles caster is not within manufacturers
alignment specifications, check for damaged suspen-
sion components or body parts. This type of damage
can cause component locations to move affecting
vehicle alignment.No adjustment can be made
for the Caster setting on this vehicle.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or any other
modification of the suspension components.
(1) Correctly position vehicle on alignment rack
and install all required equipment on vehicle, per the
alignment equipment manufacturers specifications.
(2) Center the steering wheel and lock in place
using a steering wheel clamp.
NOTE: Prior to reading each alignment specifica-
tion, jounce the front and rear of the vehicle an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Correctly jounce vehicle and read front and
rear alignment settings and compare to vehicle spec-
ifications for Camber, Caster and Toe. See Alignment
Specifications in this group of the service manual for
required specifications.If front and rear camber
readings are within required specifications pro-
ceed to step Step 3 in the Front And Rear Toe
Setting procedure. If Camber readings are not
within specifications refer to step Step 1 in the
following camber adjustment bolt package
installation procedure, for the front and rear
Camber adjustment procedure.
PLSUSPENSION 2 - 5
DIAGNOSIS AND TESTING (Continued)

COMPETITION PACKAGE ALIGNMENT PROCEDURE
If a vehicle is equipped with the optional competi-
tion package, (S/C ACR) the front wheel camber is
adjustable.
These vehicles come equipped with a special front
strut (Fig. 5). The clevis bracket (Fig. 5) used on this
strut has a slotted hole for the bottom mounting bolt.
Also, the bottom mounting bolt used on this strut has
an eccentric at the head of the bolt (Fig. 5). When the
bolt is rotated, the eccentric pushes against the
flange (Fig. 5) and a raised tab on the clevis bracket.
This forces the steering knuckle to change position
relative to strut, thus changing the camber setting of
the front wheel.
The allowable adjustment range of the front cam-
ber is from ±1.00 degrees to + 0.25 degrees.
NOTE: This vehicle is delivered from the dealer
with the camber set to the preferred specification.
The camber is only to be set to a specification that
is not the preferred camber setting when the vehi-
cle is going to be used in a competitive driving
event. The front camber must always be set back to
the preferred camber specification when the vehicle
is to be driven on the street under normal driving
conditions.
Use the following procedure for adjusting the front
camber on a vehicle equipped with the competition
package.(1) Prepare vehicle as described in the Pre-Align-
ment Vehicle Inspection procedure.
(2) Loosen the strut to steering knuckle upper
mounting bolt enough to allow the steering knuckle
to move in the strut.
(3) Loosen the strut to steering knuckle lower
mounting bolt (Fig. 5) enough to allow the bolt to
rotate in the steering knuckle and strut.
(4) Rotate the lower mounting bolt (Fig. 5) until
the desired camber setting is achieved.
(5) When camber is set to the desired specification,
tighten the strut to steering knuckle bolts to a torque
of 53 N´m (40 ft. lbs.) plus an additional 1/4 turn
after required torque is met.
FRONT AND REAR TOE SETTING PROCEDURE
(1) Prepare vehicle as described in the Pre-Align-
ment Vehicle Inspection procedure.
(2) Center steering wheel and lock in place using a
steering wheel clamp.
(3) When performing the Toe setting procedure, set
rear wheel Toe to preferred specification first, then
set front wheel Toe to the preferred specification.
(4) Loosen nuts on attaching bolts, for the left and
right rear lateral links to rear crossmember (Fig. 6).
CAUTION: When adjusting rear toe, the notches on
the lateral link adjustment cams (Fig. 7) are not to
be facing down. The notches in the adjustment
cams are only to be facing up or toward one side.
Fig. 5 Strut To Steering Knuckle Attachment With
Competitive Package.
Fig. 6 Rear Lateral Link To Crossmember Attaching
Bolts
PLSUSPENSION 2 - 7
SERVICE PROCEDURES (Continued)

(5) Rotate lateral link adjustment cams (Fig. 7)
until the preferred rear Toe specification is obtained.
See Alignment Specifications in this group of the ser-
vice manual for preferred specification.
(6) While holding Toe adjustment cams from turn-
ing, tighten left and right lateral links to rear cross-
member attaching bolt nuts. This will securely hold
adjustment cams in position. Then while holding lat-
eral link attaching bolt and adjustment cam from
turning, torque nut of lateral link attaching bolt to
95 N´m (70 ft. lbs.) (Fig. 8).CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(7) Loosen inner to outer tie rod end jam nuts (Fig.
9). Grasp inner tie rods at serrations and rotate tie
rods (Fig. 9) to set the front wheel Toe to the pre-
ferred specification. See Alignment Specifications in
this group of the service manual for preferred speci-
fication.
(8) Tighten tie rod locknuts to 54 N´m (40 ft. lbs.)
torque.
(9) Adjust steering gear to tie rod boots at tie rod.
(10) Remove steering wheel clamp.
Fig. 7 Rear Wheel Toe Adjustment Cams
Fig. 8 Torquing Rear Lateral Link Attaching Bolts
Fig. 9 Front Wheel Toe Adjustment
2 - 8 SUSPENSIONPL
SERVICE PROCEDURES (Continued)

FRONT SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 10
DESCRIPTION AND OPERATION
BALL JOINT............................ 14
COIL SPRING........................... 14
COMPETITION PACKAGE SUSPENSION...... 13
FRONT SUSPENSION.................... 11
FRONT WHEEL HUB BEARING............. 14
LOWER CONTROL ARM.................. 13
McPHERSON STRUT..................... 13
STABILIZER BAR........................ 14
STEERING KNUCKLE.................... 13
WHEEL MOUNTING STUDS................ 14
DIAGNOSIS AND TESTING
BALL JOINT ASSEMBLY................... 16
HUB/BEARING.......................... 16
LOWER CONTROL ARM.................. 15
MCPHERSON STRUT ASSEMBLY........... 15
STABILIZER BAR........................ 16
STEERING KNUCKLE.................... 15
REMOVAL AND INSTALLATION
FRONT WHEEL MOUNTING STUDS......... 28LOWER CONTROL ARM.................. 21
MCPHERSON STRUT.................... 16
STABILIZER BAR........................ 23
STEERING KNUCKLE.................... 17
WHEEL BEARING....................... 25
DISASSEMBLY AND ASSEMBLY
BALL JOINT............................ 32
LOWER CONTROL ARM FRONT
ISOLATOR BUSHING................... 33
LOWER CONTROL ARM REAR ISOLATOR
BUSHING............................ 34
McPHERSON STRUT..................... 30
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 36
SPECIFICATIONS
FRONT SUSPENSION FASTENER
TORQUES............................ 36
SPECIAL TOOLS
FRONT SUSPENSION.................... 37
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: ONLY FRAME CONTACT HOISTING
EQUIPMENT CAN BE USED ON THIS VEHICLE. All
vehicles have a fully independent rear suspension.
The vehicles can not be hoisted using equipment
designed to lift a vehicle by the rear axle. If this
type of hoisting equipment is used, damage to rear
suspension components will occur.
CAUTION: At no time when servicing a vehicle,
can a sheet metal screw, bolt or other metal fas-
tener be installed in the shock tower to take the
place of an original plastic clip. Also, NO holes can
be drilled into the front shock tower in the area
shown in (Fig. 1), for the installation of any metal
fasteners into the shock tower.
Because of the minimum clearance in this area
(Fig. 1) installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failureof the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
2 - 10 SUSPENSIONPL

(7) Place steering knuckle with wheel bearing
installed, in an arbor press with Receiver, Special
Tool MB-990799 supporting inner race of the wheel
bearing (Fig. 59). Place hub in wheel bearing making
sure it is square with bearing. Press hub into wheel
bearing until it is fully bottomed in the wheel bear-
ing.
(8) Install the steering knuckle, assembly on the
vehicle. Refer to Steering Knuckle in the Removal
And Installation section in this group of the service
manual for the required steering knuckle installation
procedure.
(9) Install the wheel and tire on the vehicle.
(10) Lower the vehicle.
(11) Set the front wheel Toe to the required speci-
fication. Refer to Wheel Alignment Check And
Adjustment Procedure in the Service Procedures Sec-
tion in this group of the service manual.
FRONT WHEEL MOUNTING STUDS
CAUTION: If a wheel attaching stud needs to be
replaced in the front hub/bearing, the stud CAN
NOT be hammered out of the hub flange. If the stud
is removed by hammering it out of the bearing
flange, damage to the hub bearing will occur lead-
ing to premature bearing failure.
The following procedure and special tools shown
MUSTbe used when replacing wheel attaching
studs.
The hub and bearing assembly does not require
removal from the steering knuckle to replace wheel
attaching studs in the hub and bearing 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, forthe required lifting procedure to be used for this
vehicle.
(2) Remove the front wheel and tire.
(3) Remove the 2 bolts (Fig. 60) attaching the disc
brake caliper to the steering knuckle .
(4) Remove the disc brake caliper from the 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 (Fig. 61).
(5) Support the disc brake caliper using a wire
hook, (Fig. 62) not by the hydraulic flex hose.
(6) Remove the rotor from the front hub (Fig. 63).
(7) Install a lug nut on the wheel stud being
removed from the hub/bearing, so threads on stud
are even with end of lug nut (Fig. 64). Rotate hub so
stud requiring removal is aligned with notch cast
into front of steering knuckle. Install Remover, Spe-
cial Tool C-4150 on hub/bearing flange and wheel
stud (Fig. 64).
Fig. 59 Pressing Hub Into Wheel Bearing
Fig. 60 Caliper Attaching Bolts
Fig. 61 Brake Caliper Removal
2 - 28 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)