2000 DODGE NEON Service Repair Manual

(2) Tighten the wheel mounting nut. This will pull
the wheel mounting stud into the flange of the hub.
When the head of the stud is fully seated against the
rear of the hub flange, remove the wheel mounting
nut and washers from the stud.
(3) Install the brake rotor on the hub (Fig. 20).
(4) Install the disc brake caliper (with pads) on the
brake rotor and steering knuckle. The left side cali-
per is installed by first sliding the top of the caliper
past the top abutment on the steering knuckle to
hook the top edge of the caliper, then pushing thelower end of the caliper into place against the
knuckle (Fig. 23). The right side caliper is installed
by first sliding the bottom edge of the caliper past
the lower abutment on the steering knuckle to hook
the lower edge of the caliper, then pushing the top of
the caliper into place against the steering knuckle.
(5) Install the two guide pin bolts securing the
front disc brake caliper to the steering knuckle (Fig.
20). Tighten the guide pin bolts to a torque of 22 N´m
(192 in. lbs.).
(6) Install the tire and wheel assembly. Install the
wheel mounting nuts and tighten them to a torque of
135 N´m (100 ft. lbs.).
(7) Lower the vehicle.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (FRONT)
The Strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
Refer to REMOVAL AND INSTALLATION in this
section for the required procedure.
For the disassembly and assembly of the strut
assembly, use strut spring compressor, Pentastar Ser-
vice Equipment (PSE) tool W-7200, or the equivalent,
to compress the coil spring. Follow the manufactur-
er's instructions closely.
DISASSEMBLY
(1) If both struts are being serviced at the same
time, mark the coil spring and strut assembly accord-
ing to which side of the vehicle the strut was
Fig. 21 Wheel Stud Removal
1 ± SPECIAL TOOL C-4150A
2 ± LUG NUT
3 ± HUB/BEARING
4 ± STEERING KNUCKLE
5 ± WHEEL STUD
Fig. 22 Installing Wheel Stud
1 ± STEERING KNUCKLE
2 ± WHEEL LUG NUT
3 ± WASHERS
4 ± HUB/BEARING
Fig. 23 Brake Caliper Installation
1 ± SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 ± BRAKING DISC
3 ± DISC BRAKE CALIPER
4 ± STEERING KNUCKLE BRAKE ABUTMENT
2 - 22 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

removed from, and which strut the coil spring was
removed from.
(2) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Set the lower hooks (Fig. 24), then set
the upper hooks (Fig. 25). Position the strut clevis
bracket straight outward away from the compressor.
Place a clamp on the lower end of the coil spring, so
the strut is held in place once the strut shaft nut is
removed (Fig. 24).
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.
(3) Compress the coil spring until all coil spring
tension is removed from the upper mount.
(4) Once the spring is sufficiently compressed,
install Strut Nut Socket, Special Tool 6864, on the
strut shaft retaining nut (Fig. 26). Next, install a
socket on the hex on the end of the strut shaft. Whileholding the strut shaft from turning, remove the nut
from the strut shaft.
Fig. 24 Strut Assembly In Compressor (Lower)
1 ± LOWER HOOKS
2 ± CLAMP
3 ± STRUT ASSEMBLY
4 ± CLEVIS BRACKET
5 ± SPRING COMPRESSOR
Fig. 25 Strut Assembly In Compressor (Upper)
1 ± NOTCH IN UPPER SEAT
2 ± UPPER MOUNT
3 ± UPPER HOOKS
4 ± CLEVIS BRACKET
Fig. 26 Shaft Nut Removal/Installation
1 ± SPRING COMPRESSOR
2 ± SPECIAL TOOL 6864
3 ± UPPER MOUNT
PLSUSPENSION 2 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

(5) Remove the upper mount from the strut shaft
(Fig. 27).
(6) Remove the upper spring seat and bearing,
along with the upper spring isolator as an assembly
from the top of the coil spring by pulling them
straight up (Fig. 27). The upper spring isolator can
be separated from the spring seat and bearing once
removed from vehicle.
(7) Remove the dust shield, then the jounce
bumper from the strut shaft by pulling each straight
up (Fig. 27).
(8) Remove the clamp from the bottom of the coil
spring and remove the strut out through the bottom
of the coil spring.
(9) Remove the lower spring isolator from the
lower spring seat on the strut.
NOTE: If the coil spring needs to be serviced, pro-
ceed with the next step, otherwise, proceed with
step 11.(10) Release the tension from the coil spring by
backing off the compressor drive completely. Push
back the compressor hooks and remove the coil
spring.
(11) Inspect the strut assembly components for the
following and replace as necessary:
²Inspect the strut for any condition of shaft bind-
ing over the full stroke of the shaft.
²Inspect the jounce bumper for cracks and signs
of deterioration.
²Check the upper mount for cracks and distortion
and its retaining studs for any sign of damage.
²Check the upper spring seat and bearing for
cracks and distortion.
²Check for binding of the upper spring seat and
bearing pivot bearing.
²Inspect the dust shield for rips and deteriora-
tion.
²Inspect the upper and lower spring isolators for
material deterioration and distortion.
²Inspect the coil spring for any sign of damage to
the coating.
ASSEMBLY
NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth-
erwise, proceed with step 3.
(1) Place the coil spring in the compressor follow-
ing the manufacturers instructions. Before compress-
ing the spring, rotate the spring so the end of the top
coil is directly in the back as shown (Fig. 28).
(2) Slowly compress the coil spring until enough
room is available for strut assembly reassembly.
(3) Install the lower spring isolator on the lower
spring seat of the strut.
(4) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. Rotate the strut as necessary
until the clevis bracket is positioned straight outward
away from the compressor (Fig. 24). Install the clamp
on the lower end of the coil spring and strut, so the
strut is held in place.
(5) Install the jounce bumper on the strut shaft.
The jounce bumper is to be installed with the smaller
end pointing downward toward the lower seat (Fig.
27).
(6) Install the dust shield on the strut shaft (Fig.
27). The bottom of the dust shield will snap past the
retainer on top of the strut housing.
(7) If disassembled, reinstall the upper spring iso-
lator on the upper spring seat and bearing.
(8) Install the upper spring seat and bearing on
top of the coil spring. Position the notch formed into
the edge of the upper seat straight out away from the
compressor (Fig. 25).
Fig. 27 Strut Assembly Components
1 ± NUT
2 ± STRUT ASSEMBLY
3 ± STRUT
4 ± LOWER SPRING ISOLATOR
5 ± COIL SPRING
6 ± JOUNCE BUMPER
7 ± DUST SHIELD
8 ± SPRING SEAT AND BEARING (WITH SPRING ISOLATOR)
9 ± UPPER MOUNT
2 - 24 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

(9) Install the strut upper mount over the strut
shaft and onto the top of the upper spring seat and
bearing.
(10) Loosely install the retaining nut on the strut
shaft. Install Strut Nut Socket (on the end of a
torque wrench), Special Tool 6864, on the strut shaft
retaining nut (Fig. 26). Next, install a socket on the
hex on the end of the strut shaft. While holding the
strut shaft from turning, tighten the strut shaft
retaining nut to a torque of 75 N´m (55 ft. lbs.).
(11) Slowly release the tension from the coil spring
by backing off the compressor drive completely. As
the tension is relieved, make sure the upper mount
and seat and bearing align properly. Verify the upper
mount does not bind.
(12) Remove the clamp from the lower end of the
coil spring and strut. Push back the spring compres-
sor upper and lower hooks, then remove the strut
assembly from the spring compressor.
(13) Install the strut assembly on the vehicle.
Refer to REMOVAL AND INSTALLATION in this
section for the required procedure.
STEERING KNUCKLE (WHEEL BEARING AND
HUB)
NOTE: The removal and installation of the wheel
bearing and hub from the steering knuckle is only
to be done with the steering knuckle removed from
the vehicle. Removal of the wheel bearing from the
steering knuckle must be done using the following
procedure.
DISASSEMBLY
(1) Remove steering knuckle, hub, and wheel bear-
ing as an assembly from the vehicle. Refer to
STEERING KNUCKLE in the REMOVAL AND
INSTALLATION section in this service manual
group.
(2) Using Remover, Special Tool 4150A, (Fig. 29)
press one wheel mounting stud out of hub flange.
Rotate the hub to align the removed wheel mounting
stud with the notch in bearing retainer plate (Fig.
30). Remove the wheel mounting stud from the hub.
(3) Rotate the hub so the hole in the hub that
wheel mounting stud was removed from is facing
away from brake caliper lower rail on steering
knuckle (Fig. 31). Install one half of the Bearing
Splitter, Special Tool 1130, between the hub and the
bearing retainer plate (Fig. 31).
NOTE: Align the threaded hole in this first half of
the bearing splitter with the caliper rail on the steer-
ing knuckle (Fig. 31).
Fig. 28 Coil Spring Positioning
1 ± UPPER END OF COIL
2 ± COIL SPRING
3 ± LOWER END OF COIL
4 ± SPRING COMPRESSOR
Fig. 29 Pressing Out Wheel Mounting Stud
1 ± SPECIAL TOOL 4150A
2 ± WHEEL MOUNTING STUD
3 ± HUB FLANGE
4 ± STEERING KNUCKLE
PLSUSPENSION 2 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Install the remaining pieces of Bearing Splitter,
Special Tool 1130, on the steering knuckle (Fig. 32).
Hand tighten the nuts to hold bearing splitter in
place on steering knuckle.
(5) Once the bearing splitter in fully installed, be
sure the three bolts attaching the bearing retainer
plate to steering knuckle (Fig. 33) are contacting the
bearing splitter (Fig. 33). The bearing retainer plate
should not support the steering knuckle or contact
the bearing splitter.
Fig. 30 Stud Removal From Hub
1 ± BEARING RETAINER PLATE
2 ± HUB
3 ± STEERING KNUCKLE
4 ± WHEEL MOUNTING STUD
5 ± NOTCH
Fig. 31 Bearing Splitter Half Installed
1 ± CALIPER RAIL
2 ± THREADED HOLE
3 ± SPECIAL TOOL 1130
4 ± STEERING KNUCKLE
5 ± HOLE FOR WHEEL MOUNTING STUD
6 ± HUB
Fig. 32 Bearing Splitter Installed
1 ± STEERING KNUCKLE
2 ± HUB
3 ± SPECIAL TOOL 1130
4 ± NUTS
Fig. 33 Correct Installation Of Bearing Splitter
1 ± STEERING KNUCKLE
2 ± SPECIAL TOOL 1130
3 ± BEARING RETAINER PLATE MOUNTING BOLTS
4 ± BEARING RETAINER PLATE
2 - 26 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

(6) Place the steering knuckle in an arbor press
supported by the bearing splitter as shown (Fig. 34).
(7) Position Driver, Special Tool 6644-2, on the
small end of the hub (Fig. 35). Using the arbor press,
remove the hub from the wheel bearing. The outer
bearing race will normally come out of the wheel
bearing when the hub is pressed out of the bearing.(8) Remove the bearing splitter from the steering
knuckle.
(9) Remove the three bolts mounting the bearing
retainer plate to the steering knuckle (Fig. 36).
Remove the bearing retainer plate from the steering
knuckle.
(10) Place the steering knuckle back in the arbor
press supported by press blocks as shown (Fig. 37).
The press blocks must not obstruct the bore in the
steering knuckle so the wheel bearing can be pressed
out of the steering knuckle. Place Bearing Driver,
Special Tool MB-990799 on the outer race of wheel
bearing (Fig. 37). Press the wheel bearing out of the
steering knuckle.
(11) Install Bearing Splitter, Special Tool 1130, on
the hub. The bearing splitter is to be installed on the
hub so it is between the flange of the hub and the
outer bearing race on the hub (Fig. 38). Place the
hub, bearing race and bearing splitter in an arbor
press as shown (Fig. 38). Place Driver, Special Tool
6644-2 on end of hub. Press the hub out of the outer
bearing race.
Fig. 34 Steering Knuckle Supporting For Hub
Removal
1 ± STEERING KNUCKLE
2 ± WHEEL BEARING
3 ± HUB
4 ± ARBOR PRESS BLOCKS
5 ± SPECIAL TOOL 1130
Fig. 35 Pressing Hub Out Of Wheel Bearing
1 ± STEERING KNUCKLE
2 ± SPECIAL TOOL 6644±2
3 ± SPECIAL TOOL 1130
4 ± ARBOR PRESS BLOCKS
5 ± HUB
Fig. 36 Wheel Bearing Retainer Plate
1 ± MOUNTING BOLTS
2 ± BEARING RETAINER PLATE
3 ± STEERING KNUCKLE
PLSUSPENSION 2 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
(1) Wipe the bore of the steering knuckle clean of
any grease or dirt with a clean, dry shop towel.
(2) Place the new wheel bearing into the bore of
the steering knuckle. Be sure the wheel bearing is
placed squarely into the bore. Place the steering
knuckle in an arbor press with Receiver, Special Tool
C-4698-2, supporting the steering knuckle (Fig. 39).
Place Driver, Special Tool 5052, on the outer race of
the wheel bearing. Press the wheel bearing into the
steering knuckle until it is fully bottomed in the bore
of the steering knuckle. Remove the knuckle from the
press.
NOTE: Only the original or identical replacement
bolts are to be used to mount the bearing retainer
plate to the steering knuckle.
(3) Install the bearing retainer plate on the steer-
ing knuckle (Fig. 40). Install the three bearing
retainer mounting bolts. Tighten the bearing retainer
plate mounting bolts to a torque of 28 N´m (250 in.
lbs.).
Fig. 37 Wheel Bearing Removal From Steering
Knuckle
1 ± ARBOR PRESS
2 ± SPECIAL TOOL MB-990799
3 ± STEERING KNUCKLE
4 ± PRESS BLOCKS
Fig. 38 Removing Bearing Race From Hub
1 ± ARBOR PRESS
2 ± HUB
3 ± SPECIAL TOOL 1130
4 ± PRESS BLOCKS (2)
5 ± BEARING RACE
6 ± SPECIAL TOOL 6644±2
Fig. 39 Pressing Wheel Bearing Into Steering
Knuckle
1 ± ARBOR PRESS
2 ± SPECIAL TOOL 5052
3 ± SPECIAL TOOL C-4698±2
4 ± STEERING KNUCKLE
5 ± WHEEL BEARING
2 - 28 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Place the previously removed wheel mounting
stud back into the hub flange. Place the hub in the
arbor press supported by Special Tool C-4698-1 (Fig.
41). Press wheel mounting stud into hub flange until
it is fully seated against the back side on the hub
flange. Remove the hub from the press.(5) Place the steering knuckle with the wheel bear-
ing installed back in the arbor press with Receiver,
Special Tool MB-990799 supporting the inner race of
the wheel bearing as shown (Fig. 42). Place the hub
in wheel bearing making sure it is square with the
bearing inner race. Press the hub into the wheel
bearing until it is fully bottomed in the wheel bear-
ing. Remove the knuckle from the press.
(6) Install the steering knuckle assembly on the
vehicle.
LOWER CONTROL ARM (BALL JOINT)
NOTE: The removal and installation of the lower
ball joint from the lower control arm is to be done
with the lower control arm removed from the vehi-
cle. Refer to LOWER CONTROL ARM in the
REMOVAL AND INSTALLATION section.
DISASSEMBLY
(1) Using a screwdriver or other suitable tool, pry
the seal boot off of the ball joint (Fig. 43).
(2) Position the Receiver, Special Tool 6908-2, on a
hydraulic press to support the lower control arm
(Fig. 44). Place the control arm on top of Tool 6908-2
so that the bottom of the ball joint sets into the
Receiver cup.
(3) Place the larger end of the Adapter, Special
Tool 6804, on top of the ball joint as shown (Fig. 44).
Fig. 40 Wheel Bearing Retainer Plate
1 ± WHEEL BEARINGS
2 ± MOUNTING BOLTS
3 ± STEERING KNUCKLE
4 ± BEARING RETAINER PLATE
Fig. 41 Wheel Mounting Stud Installation
1 ± ARBOR PRESS RAM
2 ± HUB
3 ± SPECIAL TOOL C-4698±1
4 ± NO GAP IS ALLOWED BETWEEN STUD FLANGE AND HUB
HERE
5 ± WHEEL MOUNTING STUD
Fig. 42 Pressing Hub Into Wheel Bearing
1 ± ARBOR PRESS RAM
2 ± HUB
3 ± STEERING KNUCKLE
4 ± SPECIAL TOOL MB-990799
5 ± BEARING RETAINER PLATE
6 ± WHEEL BEARING
PLSUSPENSION 2 - 29
DISASSEMBLY AND ASSEMBLY (Continued)