2000 DODGE NEON brakes

GROUP TAB LOCATORINIntroductionINaIntroduction0Lubrication and Maintenance2Suspension3Differential and Driveline5Brakes6Clutch7Cooling8ABattery8BStarting8CCharging System8DIgnition System8EInstrument Panel and Systems8EaInstrument Panel and Systems8FAudio System8GHorns8HVehicle Speed Control System8JTurn Signal and Flashers8KWindshield Wipers and Washers8LLamps8LaLamps8MRestraint System8NElectrically Heated Systems8OPower Distribution Systems8PPower Door Locks8QImmobilizer System8SPower Windows8TPower Mirrors8TaPower Mirrors8UChime Warning/Reminder System8WWiring Diagrams - LHD and RHD9Engine11Exhaust System13Frame and Bumpers14Fuel System19Steering21Transaxle22Tires and Wheels23Body24Heating and Air Conditioning24aHeating and Air Conditioning25Emission Control Systems

STEERING KNUCKLE
The front suspension steering knuckle is not a
repairable component of the front suspension. It
must be replaced if found to be damaged in any way.
If it is determined that the steering knuckle is bent
when servicing the vehicle, no attempt is to be made
to straighten the steering knuckle.
WHEEL BEARING AND HUB
The wheel bearing is designed for the life of the
vehicle and requires no type of periodic maintenance.
The following procedure may be used for diagnosing
the condition of the wheel bearing and hub.
With the wheel, disc brake caliper, and brake rotor
removed, rotate the wheel hub. Any roughness or
resistance to rotation may indicate dirt intrusion or a
failed hub bearing. If the bearing exhibits any of
these conditions during diagnosis, the hub bearing
will require replacement. The bearing is not service-
able.Damaged bearing seals and the resulting excessive
grease loss may also require bearing replacement.
Moderate grease weapage from the bearing is consid-
ered normal and should not require replacement of
the wheel bearing.
To diagnose a bent hub, refer to BRAKE ROTOR in
the DIAGNOSIS AND TESTING section in the
BRAKES service manual group for the procedure on
measuring hub runout.
LOWER CONTROL ARM
Inspect the lower control arm for signs of damage
from contact with the ground or road debris. If the
lower control arm shows any sign of damage, look for
distortion. Do not attempt to repair or straighten a
broken or bent lower control arm. If damaged, the
lower control arm stamping is serviced only as a
complete component.
The serviceable components of the lower control
arm are: the ball joint, the ball joint grease seal and
the lower control arm rear isolator bushing.
Inspect both lower control arm isolator bushings
for severe deterioration and replace as required.
Inspect the ball joint per the inspection procedure in
this section of the service manual and replace as
required. Refer to BALL JOINT in this section of this
service manual group.
BALL JOINT
With the weight of the vehicle resting on the road
wheels, grasp the headless grease fitting as shown
(Fig. 4). With no mechanical assistance or added
force, attempt to move the grease fitting. If the ball
joint is worn, the grease fitting will move. If move-
ment is noted, replace the ball joint.
Fig. 3 Strut Assembly
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
Fig. 4 Checking Ball Joint Wear
1 ± BALL JOINT
2 ± HEADLESS GREASE FITTING
PLSUSPENSION 2 - 13
DIAGNOSIS AND TESTING (Continued)

CAUTION: No attempt should be made to service
the headless grease fitting on the ball joint. It has
been purposely snapped off by the manufacturer to
avoid over-greasing.
STABILIZER BAR (FRONT)
Inspect for broken, cracked or distorted stabilizer
bar cushions and retainers. Inspect for worn or dam-
aged stabilizer bar links (Fig. 1).
SERVICE PROCEDURES
LUBRICATION
There are no serviceable lubrication points on the
front suspension. The front lower ball joints have
grease fittings which have had the head snapped off
by the manufacturer after they have been filled. This
has been done to eliminate the possibility of damag-
ing the non-vented seals. Grease will not leak from
the broken grease fittings. The ball joints are sealed
for life and require no maintenance.
CAUTION: No attempt should be made to replace
the ball joint grease fitting with a new fitting, then
filling the ball joint with grease. Damage to the
grease seal can result.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT WHILE STRUT ASSEMBLY IS INSTALLED IN
VEHICLE, OR BEFORE THE COIL SPRING IS COM-
PRESSED WITH A COMPRESSION TOOL. THE
SPRING IS HELD UNDER HIGH PRESSURE.
CAUTION: Only frame contact hoisting equipment
can be used on this vehicle. All vehicles have a
fully independent rear suspension. The vehicles
cannot 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 fastener be
installed in the shock tower to take the place of an
original plastic clip. It may come into contact with
the strut or coil spring.CAUTION: Wheel bearing damage will result if after
loosening the hub nut, the vehicle is rolled on the
ground or the weight of the vehicle is allowed to be
supported by the tires for a length of time.
STRUT ASSEMBLY (FRONT)
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 tire and wheel assembly from location
on front of vehicle requiring strut removal.
(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the screw securing the ground strap to
the rear of the strut (Fig. 5).
(5) If the vehicle is equipped with Antilock brakes
(ABS), remove the screw securing the ABS wheel
speed sensor to the rear of the strut (Fig. 5).
CAUTION: The strut assembly-to-steering knuckle
attaching bolts are serrated and must not be turned
during removal. Hold the bolts stationary in the
steering knuckle while removing the nuts, then tap
the bolts out using a pin punch.
Fig. 5 Ground Strap And ABS Sensor Bracket
1 ± ABS WHEEL SPEED SENSOR ROUTING BRACKET (IF
EQUIPPED)
2 ± GROUND STRAP
3 ± GROUND STRAP SCREW
4 ± ABS SENSOR BRACKET SCREW (IF EQUIPPED)
2 - 14 SUSPENSIONPL
DIAGNOSIS AND TESTING (Continued)

(6) Remove the two bolts attaching the strut to the
steering knuckle (Fig. 1).
(7) Lower the vehicle just enough to open the
hood, but without letting the tires touch the floor.
(8) Remove the three nuts attaching the upper
mount of the strut assembly to the vehicle's strut
tower (Fig. 6).
(9) Remove the strut assembly from the vehicle.
(10) For disassembly and assembly procedures,
refer to STRUT ASSEMBLY in the DISASSEMBLY
AND ASSEMBLY section in this section of this ser-
vice manual group.
INSTALLATION
(1) Install the strut assembly into the strut tower,
aligning the three studs on the strut upper mount
with the holes in strut tower. Install the three
mounting nuts on the studs (Fig. 6). Tighten the
three nuts to a torque of 34 N´m (300 in. lbs.).
(2) Close the hood of the vehicle.
CAUTION: The strut assembly-to-steering knuckle
attaching bolts are serrated and must not be turned
during installation. Install the nuts while holding the
bolts stationary in the steering knuckle.
(3) Position the lower end of the strut assembly in
line with the upper end of the steering knuckle and
align the mounting holes (Fig. 1). Install the two
attaching bolts. The bolts should be installed with so
that the nuts face towards the front of the vehicle
once installed. Install the nuts. Holding the bolts in
place tighten the nuts to a torque of 53 N´m (40 ft.
lbs.) plus an additional 90É turn after the specified
torque is met.(4) If the vehicle is equipped with Antilock brakes
(ABS), attach the ABS wheel speed sensor to the rear
of the strut (rearward ear) using its mounting screw
(Fig. 5). Tighten the mounting screw to a torque of
13 N´m (120 in. lbs.).
(5) Attach the ground strap to the rear of the strut
(forward ear) using its mounting screw (Fig. 5).
Tighten the mounting screw to a torque of 13 N´m
(120 in. lbs.).
(6) Install the tire and wheel assembly. Install and
tighten the wheel mounting nuts in proper sequence
until all nuts are torqued to half specification. Next,
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(7) Lower the vehicle.
STEERING KNUCKLE
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Apply the brakes and hold in place.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the front tire and wheel assembly.
(4) While the brakes are applied, loosen and
remove the hub nut on the end of the driveshaft (Fig.
7).
(5) Release the brakes.
Fig. 6 Upper Mounting Nuts
1 ± STRUT TOWER
2 ± MOUNTING NUTS
Fig. 7 Hub Nut
1 ± DRIVESHAFT
2 ± HUB
3 ± HUB NUT
PLSUSPENSION 2 - 15
REMOVAL AND INSTALLATION (Continued)

once installed. Install the nuts. Holding the bolts in
place tighten the nuts to a torque of 53 N´m (40 ft.
lbs.) plus an additional 90É turn after the specified
torque is met.
(6) Place the tie rod heat shield on the steering
knuckle arm so that the shield is positioned straight
away from the steering gear and tie rod end once
installed. Algn the hole in the shield with the hole in
the steering knucle arm.
(7) Install the outer tie rod ball stud into the hole
in the steering knuckle arm. Start the tie rod attach-
ing nut onto the stud. Hold the tie rod end stud with
a wrench while tightening the nut with a standard
wrench or crowfoot wrench (Fig. 9). To fully tighten
the nut to specifications, use a crowfoot wrench on a
torque wrench to turn the nut, and a wrench on the
stud. Tighten the nut to a torque of 55 N´m (40 ft.
lbs.).
(8) Install the brake rotor on the hub (Fig. 8).
(9) 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 the
lower end of the caliper into place against the
knuckle (Fig. 13). 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.
(10) Install the two guide pin bolts securing the
front disc brake caliper to the steering knuckle (Fig.
8). Tighten the guide pin bolts to a torque of 22 N´m
(192 in. lbs.).(11) Clean all foreign matter from the threads of
the driveshaft outer C/V joint (Fig. 7).
(12) Install the hub nut in the end of the drive-
shaft and snug it.
(13) Have a helper apply the brakes. With vehicle
brakes applied to keep brake rotor and hub from
turning, tighten the hub nut to a torque of 244 N´m
(180 ft. lbs.)
(14) Install the tire and wheel assembly. Install
the wheel mounting nuts and tighten them to a
torque of 135 N´m (100 ft. lbs.).
(15) Lower the vehicle.
(16) Set the front toe on the vehicle to required
specification. Refer to WHEEL ALIGNMENT in this
service manual group.
LOWER CONTROL ARM
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 front tire and wheel assembly.
(3) Remove both stabilizer bar links from the vehi-
cle (Fig. 14). Remove each link by holding the upper
retainer/nut with a wrench and turning the link bolt.
(4) Rotate the forward ends of the stabilizer bar
downward. It may be necessary to loosen the stabi-
Fig. 13 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
Fig. 14 Stabilizer Bar Links
1 ± STABILIZER BAR CUSHION RETAINERS
2 ± CUSHIONS
3 ± FRONT STABILIZER BAR
4 ± STABILIZER BAR LINKS
2 - 18 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

For more information on the description and oper-
ation of an individual component, refer to the appli-
cable component heading in this section.
STRUT ASSEMBLY (REAR)
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around
struts. The coil springs are contained between the
upper mount of the strut assembly and a lower
spring seat on the body of the strut.
The top of each strut assembly is bolted to the top
of the inner fender through a rubber isolated mount.
The bottom of the strut assembly attaches to the rear
knuckle using 2 thru-bolts with prevailing torque
nuts.
The rear strut assembly includes the following
components (Fig. 1): A rubber isolated upper mount,
a dust shield, a jounce bumper, a coil spring, a lower
spring isolator, and a strut. Any component in need
of service requires removal of the strut assembly
from the vehicle and disassembly of it.
COIL SPRING
Rear coil springs are rated separately for each cor-
ner or side of the vehicle depending on optional
equipment and type of vehicle service. If a coil spring
requires replacement, be sure the spring needing
replacement is replaced with a spring meeting the
correct load rating for the vehicle with its specific
options.
KNUCKLE (REAR)
A forged rear knuckle bolts to each rear strut
assembly (Fig. 1). The rear knuckle's spindle sup-
ports the rear hub and bearing. Together they sup-
port the rear tire and wheel. The movement of the
rear knuckle is controlled laterally using two lateral
arms attached to the knuckle. Fore and aft move-
ment of the knuckle is controlled by using a tension
strut.
HUB AND BEARING (REAR)
The hub and bearing is mounted on the rear
knuckle's spindle (Fig. 1). The hub and bearing
adapts the tire and wheel assembly to the knuckle.
It's bearing allows the tire and wheel assembly to
rotate freely on the vehicle.
All vehicles are equipped with permanently lubri-
cated and sealed for life rear wheel bearings. There
is no periodic lubrication or maintenance recom-
mended for these units.
The only servicable components of the hub and
bearing are the wheel mounting studs.
If a vehicle is equipped with antilock brakes, the
tone wheels for the rear wheel speed sensors are
pressed onto the hub.
LATERAL ARMS
The lateral arms control the lateral movement of
the rear suspension, specifically the knuckle (Fig. 1).
There are two lateral arms per side of the rear sus-
pension. One arm is attached to the front end of the
knuckle and the other is attached to the rear of the
knuckle. The other end of each lateral arm attaches
to the rear crossmember.
Visually it appears that the left rear arm is
mounted backwards in relation to the other arms
(Fig. 2). Although the left rear arm looks like it is
same as the right rear arm, just reversed, it is not
the same; the arms are not interchangeable.
The front arms are interchangeable, but should be
mounted with the side displaying the word ªFOR-
WARDº stamped into it toward the front of the vehi-
cle. The trimmed outer edge of the arms will then be
facing the rear of the vehicle.
1 ± VEHICLE STRUT TOWER
2 ± STRUT ASSEMBLY
3 ± TENSION STRUT
4 ± LATERAL ARMS
5 ± KNUCKLE
6 ± HUB AND BEARING
7 ± WHEEL ALIGNMENT ADJUSTMENT CAM
8 ± STRUT9 ± LOWER SPRING ISOLATOR
10 ± COIL SPRING
11 ± STABILIZER BAR
12 ± JOUNCE BUMPER
13 ± DUST SHIELD
14 ± UPPER MOUNT
15 ± STABILIZER BAR LINK
16 ± STABILIZER BAR CUSHION AND RETAINER
PLSUSPENSION 2 - 37
DESCRIPTION AND OPERATION (Continued)

KNUCKLE (REAR)
The rear knuckle is not a repairable component of
the rear suspension. Upon visual inspection, if it is
determined that the knuckle is cracked, bent or bro-
ken, no attempt is to be made to repair or to
straighten the knuckle. The knuckle must be
replaced if found to be damaged in any way.
HUB AND BEARING (REAR)
The hub and bearing is designed for the life of the
vehicle and requires no type of periodic maintenance
(Fig. 1). The following procedure may be used for
diagnosing the condition of the hub and bearing.
With the wheel, disc brake rotor or brake drum
removed, rotate the hub. Any roughness or resistance
to rotation may indicate dirt intrusion or a failed hub
bearing. If the bearing exhibits any of these condi-
tions during diagnosis, the hub and bearing will
require replacement. The bearing is not serviceable
alone.
Damaged bearing seals and the resulting excessive
grease loss may also require hub and bearing
replacement. Moderate grease weapage from thebearing is considered normal and should not require
replacement of the wheel bearing.
To diagnose a bent hub, refer to BRAKE ROTOR in
the DIAGNOSIS AND TESTING section in the
BRAKES service manual group for the procedure on
measuring hub runout.
LATERAL ARMS
Inspect each lateral arm (Fig. 1). Look for signs of
contact with an object that has caused damage to the
lateral arm. If the lateral arm is bent or damaged,
the lateral arm will require replacement. Do not
attempt to repair or straighten a lateral arm.
Inspect the lateral arm isolator bushings and their
sleeves for signs of damage or deterioration. If dam-
age or deterioration is present, replacement of the
entire lateral arm will be required. The isolator
bushings cannot be serviced separately from the lat-
eral arms.
TENSION STRUT
Inspect the tension strut (Fig. 1). Look for signs of
contact with any object that has bent or caused other
damage to the tension strut. If the tension strut is
bent or damaged, the tension strut will require
replacement. Do not attempt to repair or straighten a
tension strut.
Inspect the tension strut front (spool type) bushing,
and rear (bayonet type) bushings and retainers for
signs of deterioration or damage. If the front bushing
is damaged or shows signs of deteriation, the tension
strut must be replaced. The front bushing cannot be
replaced separately. If the rear bushings are deterio-
rated or damaged, or the retainers are damaged,
replacement is necessary. The bushings and retainers
can be replaced separately from the tension strut.
STABILIZER BAR (REAR)
Inspect the stabilizer bar (Fig. 1). Look for damage
or bending. If damage is evident, the bar must be
replaced.
Inspect for broken, cracked or distorted stabilizer
bar cushions and cushion retainers. The horizontal
slit at the front of each cushion is supposed to be
there. If damage is evident, the cushions can be
replaced separately from the stabilizer bar utilizing
the horizontal slit.
Inspect the stabilizer bar links that attach the sta-
bilizer bar to each rear strut. Look for damage or
deterioration of the bushings on the ends of each
link. Inspect the stabilizer bar link to ensure it is not
bent or broken. If any of these conditions are present,
the stabilizer bar link must be replaced. The links
can be replaced separately from the stabilizer bar.
Fig. 4 Strut Assembly
1 ± STRUT ASSEMBLY
2 ± STRUT
3 ± LOWER SPRING ISOLATOR
4 ± COIL SPRING
5 ± JOUNCE BUMPER
6 ± DUST SHIELD
7 ± UPPER MOUNT
PLSUSPENSION 2 - 39
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT WHILE STRUT ASSEMBLY IS INSTALLED IN
VEHICLE, OR BEFORE THE COIL SPRING IS COM-
PRESSED WITH A COMPRESSION TOOL. THE
SPRING IS HELD UNDER HIGH PRESSURE.
CAUTION: Only frame contact or wheel lift hoisting
equipment can be used on vehicles having a fully
independent rear suspension. Vehicles with inde-
pendent rear suspension can not be hoisted using
equipment designed to lift a vehicle by the rear
axle. If this type of hoisting equipment is used dam-
age to rear suspension components will occur.
NOTE: If a rear suspension component becomes
bent, damaged or fails, no attempt should be made
to straighten or repair it. Always replace it with a
new component.
STRUT ASSEMBLY (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 the rear wheel and tire assembly from
the vehicle.
(3) If the vehicle is equipped with rear drum
brakes, remove the screw securing the brake hose
bracket to the rear of the strut assembly (Fig. 5).
(4) If the vehicle is equipped with the antilock
brake system (ABS), remove the screw securing the
ABS wheel speed sensor bracket to the rear of the
strut assembly (Fig. 6).
(5) Remove the nut from the end of the rear stabi-
lizer bar link bolt (Fig. 5). Pull the bolt out through
the top of the link and remove the link.
(6) If the vehicle is equipped with rear disc brakes
(Fig. 7), perform the following:
²Remove the two guide pin bolts securing the
front disc brake caliper to the steering knuckle.
²Remove the disc brake caliper from the knuckle
and brake rotor.²Hang the caliper out of the way using a wire
hanger or cord. Do not support the caliper by letting
it hang by the hydraulic hose.
Fig. 5 Rear of Strut Assembly
1 ± BRAKE HOSE BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
Fig. 6 Rear of Strut Assembly with ABS
1 ± ABS WHEEL SPEED SENSOR BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
2 - 40 SUSPENSIONPL