2000 DODGE NEON Service Repair Manual

(10) With suspension at curb height, tighten the
lateral arm mounting bolt nut at the crossmember to
88 N´m (65 ft. lbs.).
(11) Set the rear toe on the vehicle to the required
specification as necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
TENSION STRUT
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) Disconnect the tension strut from the knuckle.
To do this, first hold the tension strut from turning
by using a wrench on the flat on the tension strut
and then remove the nut from the rear of the tension
strut (Fig. 14). Next, remove the tension strut
retainer, then the rear tension strut bayonet bushing
from the tension strut.
(4) Remove the nut attaching the parking brake
cable to the stud on the inboard tension strut mount-
ing bolt at the frame (Fig. 15). Remove the parking
brake cable from the stud.
(5) Remove the two mounting bolts holding the
tension bolts to the frame, then remove the tension
strut from the vehicle.(6) Remove the forward bayonet bushing and
retainer from the tension strut.
INSTALLATION
(1) Install the forward retainer and a bayonet
bushing on the tension strut trailing end. Be sure the
stepped area of the bushing is installed to face the
knuckle.
(2) To install the knuckle on the tension, first stick
the trailing end through the hole in the lower end of
the knuckle, seating the bayonet bushing squarely
against the hole. Next, raise the end of the tension
strut with the spool bushing into its mounting posi-
tion on the frame (Fig. 15). Install the mounting
bolts securing the tension strut to the frame.
Remember, the mounting bolt with the stud on the
head is installed on the inboard side.
(3) Tighten the two mounting bolts at the frame to
a torque of 95 N´m (70 ft. lbs.).
(4) Place the parking brake cable routing bracket
on the stud of the inboard mounting bolt and install
the nut securing it in place (Fig. 15). Tighten the nut
to a torque of 28 N´m (250 in. lbs.).
(5) Install the rear bayonet bushing on the tension
strut. Be sure the stepped area of the bushing is
squarely seated into the hole in the knuckle.
(6) Install the rear tension strut retainer, then the
nut. To completely install the nut, place a wrench on
the flat formed into the tension strut and tighten the
nut (Fig. 14). Tighten the nut to a torque of 95 N´m
(70 ft. lbs.).
(7) Install the tire and wheel assembly. Tighten
the wheel mounting nuts in proper sequence until all
Fig. 14 Tension Strut Nut Removal/Installation
1 ± KNUCKLE
2 ± TENSION STRUT
3 ± FLAT
Fig. 15 Tension Strut Mounting At Frame
1 ± TENSION STRUT MOUNTING BOLTS
2 ± TENSION STRUT
3 ± SPOOL BUSHING
4 ± NUT
5 ± PARKING BRAKE CABLE
2 - 46 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

nuts are torqued to half specification. Repeat the
tightening sequence, this time, to full specified
torque of 135 N´m (100 ft. lbs.).
(8) Lower the vehicle to ground level.
(9) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
STABILIZER BAR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both rear wheel and tire assemblies
from the vehicle.
(3) Remove the nut from the end of each rear sta-
bilizer bar link bolt (Fig. 16). Pull the bolt out
through the top of the link and remove the link from
each end of the stabilizer bar.
(4) Remove the two bolts securing each of the two
cushion retainers to the frame rails (Fig. 1), then
remove the cushion retainers, cushions and stabilizer
bar from the vehicle as an assembly.
(5) Pull the cushion retainers off the cushions.
(6) The cushions can be removed from the bar by
utilizing the pre-formed slit in each cushion and peel-
ing it off the bar.
INSTALLATION
(1) Install the cushions on the stabilizer bar by
opening the slit in the cushion and wrapping the
cushion around the bar. When installed properly, the
slit in the cushion should face in the same direction
as the ends of the stabilizer bar, or toward the front
of the car once the bar is installed. The flat side of
each cushion should face upward.
(2) Install the retainers on the cushions, matching
the contour of each retainer with its cushion.
(3) Install the stabilizer bar, cushions and retain-
ers on the car as an assembly. The dipped area in the
center of the bar must face down to clear the well in
the luggage compartment.
(4) Install two bolts in each cushion retainer and
secure the stabilizer bar to the frame of the vehicle
(Fig. 1). Do not completely install the bolts at this
time.
(5) Reinstall each stabilizer bar link (Fig. 1):
²Place the link center sleeve and bushings
between the eye in the end of the stabilizer bar and
the link mounting bracket on the strut.
²Start the stabilizer bar link bolt with bushing
from the top, down through the stabilizer bar, inner
link bushings and sleeve, and strut link mounting
bracket.
²Install a lower bushing, then the nut. Do not
tighten the nut at this time.
(6) Install both tire and wheel assemblies on the
vehicle. Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Repeat the tightening sequence, this
time, to full specified torque of 135 N´m (100 ft. lbs.).
(7) Lower the vehicle to ground level or curb
height.
(8) Tighten the rear stabilizer bar cushion retainer
bolts to a torque of 34 N´m (300 in. lbs.).
(9) Tighten the stabilizer bar link nuts to a torque
of 23 N´m (200 in. lbs.).
(10) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (REAR)
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.
Fig. 16 Stabilizer Bar Link
1 ± BRAKE HOSE BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
PLSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

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
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, then upper hooks on the
coil spring (Fig. 17). Position the strut clevis bracket
straight inward toward 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.
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. 18). Next, install a
socket on the hex on the end of the strut shaft. While
holding the strut shaft from turning, remove the nut
from the strut shaft.
(5) Remove the upper mount from the strut shaft
(Fig. 19).
(6) Remove the clamp from the bottom of the coil
spring and remove the strut out through the bottom
of the coil spring.
(7) Remove the dust shield, then the jounce
bumper from the strut shaft by pulling each straight
up (Fig. 19).
(8) Remove the lower spring isolator from the
lower spring seat located on the strut.
NOTE: If the coil spring needs to be serviced, pro-
ceed with the next step, otherwise, proceed with
step 10.
NOTE: Before removing the coil spring from the
compressor, make not of its position in the com-
pressor, for easy reassembly.
(9) Release the tension from the coil spring by
backing off the compressor drive completely. Push
back the compressor hooks and remove the coil
spring.
(10) 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.
Fig. 17 Strut Assembly In Compressor
1 ± UPPER HOOKS
2 ± COIL SPRING
3 ± CLEVIS BRACKET
4 ± CLAMP
5 ± LOWER HOOKS
Fig. 18 Shaft Nut Removal/Installation
1 ± UPPER MOUNT
2 ± FRONT HOOK
2 - 48 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Check the upper mount for cracks and distortion
and its retaining studs for any sign of damage.
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 to the position
determined in the note prior to step 9 in disassembly.
(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 matching the step built intothe isolator with the step in the lower spring seat on
the strut (Fig. 19).
(4) Install the jounce bumper on the strut shaft.
The jounce bumper is to be installed with the pointed
end pointing downward toward the lower seat.
(5) Install the dust shield on the strut shaft (Fig.
19). The bottom of the dust shield will snap past the
retainer on top of the strut housing.
(6) 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 until the end
of the coil spring fits against the step in the lower
spring seat (Fig. 17). If done correctly, the clevis on
the bottom of the strut should face toward the com-
pressor.
(7) Install the clamp on the lower end of the coil
spring and strut, so the strut is held in place with
the coil spring.
NOTE: Before installing the upper mount, check to
make sure the correct side mount is being installed.
Left and right upper mounts are different. A left
mount will be marked with the letter ªLº while a
right mount will be marked with the letter ªRº (Fig.
20).
(8) Install the upper mount over the strut shaft
and onto the top of the upper spring. Near the center
on the top of the mount is the word ªOUTº and an
arrow (Fig. 20). Point the arrow on the mount in the
same direction that the clevis bracket on the lower
end of the strut is pointed in. This direction should
be straight toward the compressor.
(9) 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. 18). Next, install a socket on the
Fig. 19 Strut Assembly Components
1 ± STRUT ASSEMBLY
2 ± STRUT
3 ± LOWER SPRING ISOLATOR
4 ± COIL SPRING
5 ± JOUNCE BUMPER
6 ± DUST SHIELD
7 ± UPPER MOUNT
Fig. 20 Upper Mount Markings
1 ± SIDE INDICATING LETTER
2 ± DIRECTIONAL INDICATOR
3 ± UPPER MOUNT
PLSUSPENSION 2 - 49
DISASSEMBLY AND ASSEMBLY (Continued)

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.).
(10) 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's
seat aligns properly with the coil spring.
(11) Verify the arrow on the upper mount is point-
ing in the same direction as the strut clevis bracket
as mentioned in step 9.
(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.
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STRUT ASSEMBLY:
Tower Attaching Nuts..... 34N´m(300 in. lbs.)
Knuckle Attaching Bolts.... 88N´m(65ft.lbs.)
Strut Assembly Shaft Nut . . . 75 N´m (55 ft. lbs.)
Brake Hose Bracket Mounting Bolt..... 31N´m
(275 in. lbs.)
KNUCKLE:
Brake Support Plate Mounting Bolts.... 75N´m
(55 ft. lbs.)
Disc Brake Adapter Mounting Bolts.... 75N´m
(55 ft. lbs.)
HUB AND BEARING:
To Knuckle Retaining Nut........... 217N´m
(160 ft. lbs.)
Wheel Mounting Nuts...........109-150 N´m
(80-110 ft. lbs.)
LATERAL ARM:
Nut At Crossmember....... 88N´m(65ft.lbs.)
Nut At Knuckle........... 95N´m(70ft.lbs.)
TENSION STRUT:
Rear Nut................ 95N´m(70ft.lbs.)
Frame Rail Bolts.......... 95N´m(70ft.lbs.)
Parking Brake Cable Nut . . 28 N´m (250 in. lbs.)
STABILIZER BAR:
Cushion Retainer Bolts.... 34N´m(300 in. lbs.)
Link Bolt Nut........... 23N´m(200 in. lbs.)
SPECIAL TOOLS
REAR SUSPENSION
Socket/Wrench Strut Rod Nut 6864
2 - 50 SUSPENSIONPL
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL AND DRIVELINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FRONT DRIVESHAFTS.....................1
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS...................2
REMOVAL AND INSTALLATION
DRIVESHAFTS...........................3
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION................7INNER TRIPOD JOINT SEAL BOOT...........7
OUTER C/V JOINT SEAL BOOT.............13
SPECIFICATIONS
TORQUE...............................17
SPECIAL TOOLS
DRIVESHAFT............................17
DESCRIPTION AND OPERATION
FRONT DRIVESHAFTS
Vehicles equipped with either an automatic or
manual transmission use an unequal±length drive-
shaft system.The system incorporates two driveshaft assemblies
(left and right) that consist of an inner and outer
constant velocity (CV) joint and a solid interconnect-
ing shaft (Fig. 1). The right driveshaft is longer than
the left due to transaxle packaging and powertrain
design.
Fig. 1 Unequal Length Driveshaft System
1 ± STUB AXLE
2 ± OUTER C/V JOINT
3 ± OUTER C/V JOINT BOOT
4 ± TUNED RUBBER DAMPER WEIGHT
5 ± INTERCONNECTING SHAFT
6 ± OUTER C/V JOINT BOOT
7 ± STUB AXLE8 ± OUTER C/V JOINT
9 ± RIGHT DRIVESHAFT
10 ± INNER TRIPOD JOINT BOOT
11 ± INNER TRIPOD JOINT
12 ± INNER TRIPOD JOINT
13 ± INNER TRIPOD JOINT BOOT
14 ± INTERCONNECTING SHAFT LEFT DRIVESHAFT
PLDIFFERENTIAL AND DRIVELINE 3 - 1

Driveshafts used on both the right and left sides of
the vehicle use a tuned rubber damper weight
mounted to the interconnecting shaft (Fig. 1). 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
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 single
piece steel hub nut (Fig. 2). The hub nut is a locking
style; the nut lock, anti-rattle washer, and cotter pin
are not necessary.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.
Fig. 2 Driveshaft Retaining Nut
1 ± DRIVESHAFT
2 ± HUB
3 ± HUB NUT
3 - 2 DIFFERENTIAL AND DRIVELINEPL
DESCRIPTION AND OPERATION (Continued)

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
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) Disconnect battery negative cable.
(2) Place transaxle in gated park.
(3) Raise vehicle on hoist.
(4) Remove wheel and tire assembly (Fig. 3).(5) Remove the driveshaft to hub and bearing
retaining nut (Fig. 4).
(6) If equipped with ABS, disconnect the front
wheel speed sensor and secure harness out of the
way.
Fig. 3 Wheel and Tire Removal
1 ± WHEEL/TIRE ASSY.
2 ± LUG NUT (5)
3 ± HUB
Fig. 4 Driveshaft Retaining Nut Removal
1 ± DRIVESHAFT
2 ± HUB
3 ± HUB NUT
PLDIFFERENTIAL AND DRIVELINE 3 - 3
DIAGNOSIS AND TESTING (Continued)