1999 DODGE NEON suspension

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to. Use the schedule that best
describes these conditions.
Schedule ±A, lists maintenance recommended for
vehicles used for general transportation.
Schedule ±B, lists maintenance recommended for
vehicles used under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Frequent trailer towing
²Extensive idling
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)
Where time and mileage are listed, follow the
interval that occurs first.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery, clean, and tighten terminals as
required.
²Check fluid levels of coolant reservoir, power
steering and automatic transmission and add as
required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on schedule ± B (6,000 miles).
²Check coolant level, hoses and clamps.
²Check the manual transaxle fluid level.
²If the mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Replace engine oil filter.
²Lubricate front suspension ball joints.
²Adjust drive belt tension.
PLLUBRICATION AND MAINTENANCE 0 - 3

²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
²Adjust drive belt tension.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
52,500 Miles (84 000 km) or at 42 months
²Change engine oil.
²Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
²Change engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Replace drive belts.
²Replace air cleaner element.
²Replace ignition cables.
²Replace spark plugs.
²Change automatic transmission fluid.
67,500 Miles (108 000 km) or at 54 months
²Change engine oil.
²Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km) or at 60 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change engine oil.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Inspect front brake pads and rear brake linings.²Adjust drive belt tension.
²Replace air cleaner air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid.
97,500 Miles (156 000 km) or at 78 months
²Change engine oil.
105,000 Miles (168 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace engine timing belt
²Adjust drive belt tension.
SCHEDULE ± B
NOTE: * Follow this schedule if you usually operate
your vehicle under one or more of the following
conditions. Change the automatic transmission
fluid and filter every 15,000 miles (24 000 km) if you
usually operate your vehicle under one of the con-
ditions marked with an *.
3,000 Miles (5 000 km)
²Change engine oil
6,000 Miles (10 000 km)
²Change engine oil
²Replace engine oil filter.
9,000 Miles (14 000 km)
²Change engine oil
²Inspect front brake pads and rear brake lining.
12,000 Miles (19 000 km)
²Change engine oil
²Replace engine oil filter.
15,000 Miles (24 000 km)
²Change engine oil
²Adjust drive belt tension.
²Inspect and replace, if required, the air
cleaner element.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
18,000 Miles (29 000 km)
²Change engine oil
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
21,000 Miles (34 000 km)
²Change engine oil
0 - 4 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

24,000 Miles (38 000 km)
²Change engine oil
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil
²Inspect front brake pads and rear brake linings.
30,000 Miles (48 000 km)
²Change engine oil
²Replace engine oil filter.
²Check and replace, if necessary, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Adjust drive belt tension.
²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid and filter.
Adjust the bands.*
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Flush and replace engine coolant.
²Inspect front brake pads and rear brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
²Inspect and replace, if necessary, the air
cleaner element.
²Adjust drive belt tension.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Replace drive belts.
²Replace air cleaner element.
²Replace ignition cables.
²Replace spark plugs.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
63,000 Miles (101 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Adjust drive belt tension.
²Inspect and replace, if necessary, the air
cleaner element.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Flush and replace the engine coolant.
²Inspect front brake pads and rear brake linings.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
87,000 Miles (139 000 km)
²Change engine oil.
PLLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Adjust drive belt tension.
²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
102,000 Miles (163 000km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000km)
²Replace the engine timing belt
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
²Inspect and replace, if necessary, the air
cleaner element.
NOTE: **This maintenance is recommended by
Chrysler to the owner but is not required to main-
tain the warranty on the PCV valve.
NOTE: ***This maintenance is not required if the
PCV valve was previously replaced.
0 - 6 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR
TOW VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust
system, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do not
secure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing overrough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²5-speed manual transaxle vehicles can be flat
towed at any legal highway speed for extended dis-
tances. The gear selector must be in the neutral posi-
tion.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²Verify that front drive line and steering compo-
nents are in good condition.
²5-speed manual transaxle vehicles can be towed
at any legal highway speed for extended distances.
The gear selector must be in the neutral position.
²3-speed automatic transaxle vehicles can be
towed at speeds not to exceed 40 km/h (25 mph) for
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCEPL
SERVICE PROCEDURES (Continued)

not more than 25 km (15 miles). The gear selector
must be in the neutral position.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components, damage to vehicle can result.
Do not attempt to raise one entire side of the
vehicle by placing a floor jack midway between the
front and rear wheels. This practice may result in
permanent damage to the body.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a PL vehicle (Fig. 3). Support the vehicle in the
raised position with jack stands.
A floor jack must never be used on any part of the
underbody.
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 3).
Fig. 3 Hoisting and Jacking Points
PLLUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)

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)