2000 DODGE NEON torque strut

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Front End Whine On
Turns1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or
Grinding On Turns1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Engine Mount Grounding
Against Frame Or Body Of Vehicle.2. Check For Motor Mount Hitting Frame
Rail And Reposition Engine As Required
3. Worn Or Broken C/V Joint 3. Replace C/V Joint
4. Loose Wheel Lug Nuts 4. Verify Wheel Lug Nut Torque
5. Incorrect Wheel Alignment 5. Check And Reset Wheel Alignment
6. Worn Tires 6. Replace Tires
Front End Clunk Or
Snap On Turns1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
3. Worn Or Loose Tie Rod Or Ball Joint 3. Tighten Or Replace Tie Rod End Or Ball
Joint
4. Worn Control Arm Bushing 4. Replace Control Arm Bushing
5. Loose Sway Bar Or Upper Strut
Attachment5. Tighten Sway Bar Or Upper Strut
Attachment To Specified Torque
Front End Whine
With Vehicle Going
Straight At A
Constant Speed1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or
Grinding With
Vehicle Going
Straight At A
Constant Speed1. Engine Mount Grounding 1. Reposition Engine As Required
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
Front End Whine
When Accelerating
Or Decelerating1. Worn Or Defective Transaxle Gears Or
Bearings1. Replace Transaxle Gears Or Bearings
Front End Clunk
When Accelerating
Or Decelerating1. Worn Or Broken Engine Mount 1. Replace Engine Mount
2. Worn Or Defective Transaxle Gears Or
Bearings2. Replace Transaxle Gears Or Bearings
PLSUSPENSION 2 - 3

CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
3. Loose Wheel Lug Nuts 3. Verify Wheel Lug Nut Torque
4. Worn Or Broken C/V Joint 4. Replace C/V Joint
5. Worn Or Loose Ball Joint 5. Tighten Or Replace Ball Joint
6. Worn Or Loose Control Arm Bushing 6. Tighten To Specified Torque Or Replace
Control Arm Bushing
7. Loose Crossmember Bolts 7. Tighten Crossmember Bolts To Specified
Torque
Road Wander 1. Incorrect Tire Pressure 1. Inflate Tires To Rcommended Pressure
2. Incorrect Front Or Rear Wheel Toe 2. Check And Reset Front Wheel Toe
3. Worn Wheel Bearings 3. Replace Wheel Bearing
4. Worn Control Arm Bushings 4. Replace Control Arm Bushing
5. Excessive Friction In Steering Gear 5. 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 Play1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends
3. Loose Steering Gear Mounting Bolts 3. Tighten Steering Gear Bolts To The
Specified Torque
4. Loose Or Worn Steering Shaft Coupler 5. Replace Steering Shaft Coupler
Excessive Steering
Effort1. Low Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Lack Of Lubricant In Steering Gear 2. 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. Check and replace automatic belt
tensioner as necessary. If drive belt is worn
or glazed, replace belt.
5. Lack Of Lubricant In Steering Ball Joints 5. Lubricate Or Replace Steering Ball Joints
6. Steering Gear Malfunction 6. Replace Steering Gear
7. Lack Of Lubricant In Steering Coupler 7. Replace Steering Coupler
2 - 4 SUSPENSIONPL
DIAGNOSIS AND TESTING (Continued)

(4) Install a nut provided in adjustment package
on the replacement bolt. Tighten the nut until it's
snug, but still allowing the knuckle to slide in the
clevis bracket.
(5) Remove the original lower bolt.
(6) Install a bolt from the adjustment package into
the bottom hole of the strut clevis bracket. Install the
bolt from the rear.
(7) Install a nut provided in adjustment package
on the replacement bolt. Tighten the nut until it's
snug.
(8) Reinstall the tire and wheel assembly.
(9) Perform the above procedure to any of the
remaining struts as required.
(10) Lower the vehicle and jounce the front and
rear of the vehicle.
(11) Adjust the front or rear camber to the pre-
ferred setting by pushing or pulling on the top of the
tire. When camber is set to specifications, tighten the
upper and lower strut clevis bracket bolts. Again
jounce the front and rear of the vehicle, then verify
the camber settings.
(12) Torque front strut clevis bracket-to-steering
knuckle attaching bolts to 53 N´m (40 ft. lbs.), plus
an additional 1/4 turn after the torque is met. Torque
the rear strut clevis bracket-to-rear knuckle attach-
ing bolts to 95 N´m (70 ft. lbs.).
(13) Once camber is within specifications, adjust
toe to meet the preferred specification setting. Refer
to TOE within this wheel alignment service proce-
dure.
TOE
(1) Center the steering wheel and lock it in place
using a steering wheel clamp.
NOTE: When performing the toe setting procedure,
make sure the rear toe is set to the preferred spec-
ification before setting the front toe to the preferred
specification.
REAR TOE
(1) Loosen the nuts on the left and right rear lat-
eral link attaching bolts at the rear crossmember as
necessary to allow rotation of the rear toe adjustment
cams (Fig. 4).CAUTION: When adjusting rear toe, the notches on
the toe adjustment cams are not to be facing down.
The notches in the adjustment cams are only to be
facing up or toward one side.
(2) Rotate each toe adjustment cam until the pre-
ferred rear toe specification is obtained (Fig. 4). Refer
to WHEEL ALIGNMENT SPECIFICATIONS in this
section of this service manual group.
(3) While holding the toe adjustment cams from
turning, tighten the attaching bolt nuts. This will
securely hold the adjustment cams in position.
Tighten the attaching bolt nuts to a torque of 88 N´m
(65 ft. lbs.).
(4) Proceed to FRONT TOE to set the front toe.
FRONT TOE
CAUTION: Do not twist the inner tie rod-to-steering
gear rubber boots while turning the inner tie rod
during the front toe adjustment.
(1) Loosen the tie rod adjusting jam nuts (Fig. 5).
Grasp each inner tie rod at its hex and rotate it one
way or the other until the front wheel toe is set to
the preferred specification. Refer to WHEEL ALIGN-
MENT SPECIFICATIONS in this section of this ser-
vice manual group.
Fig. 4 Adjustment Cams
1 ± BOLTS
2 ± ADJUSTMENT CAMS
3 ± NUTS
PLSUSPENSION 2 - 7
SERVICE PROCEDURES (Continued)

FRONT SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FRONT SUSPENSION SYSTEM...............9
STRUT ASSEMBLY (FRONT)................11
STEERING KNUCKLE.....................11
LOWER CONTROL ARM...................11
STABILIZER BAR (FRONT).................12
DIAGNOSIS AND TESTING
STRUT ASSEMBLY (FRONT)................12
STEERING KNUCKLE.....................13
WHEEL BEARING AND HUB................13
LOWER CONTROL ARM...................13
BALL JOINT.............................13
STABILIZER BAR (FRONT).................14
SERVICE PROCEDURES
LUBRICATION...........................14
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........14STRUT ASSEMBLY (FRONT)................14
STEERING KNUCKLE.....................15
LOWER CONTROL ARM...................18
STABILIZER BAR (FRONT).................20
WHEEL MOUNTING STUD (FRONT)..........21
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (FRONT)................22
STEERING KNUCKLE (WHEEL BEARING AND
HUB).................................25
LOWER CONTROL ARM (BALL JOINT)........29
LOWER CONTROL ARM (REAR ISOLATOR
BUSHING).............................31
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
SPECIFICATIONS.......................33
SPECIAL TOOLS
FRONT SUSPENSION.....................33
DESCRIPTION AND OPERATION
FRONT SUSPENSION SYSTEM
The front suspension allows each front wheel on a
vehicle to adapt to different road surfaces and condi-
tions without greatly affecting the opposite wheel
and the ability to control the vehicle. Each side of the
front suspension is allowed to pivot so the vehicle can
be steered in the direction preferred.
This vehicle has a gas pressurized MacPherson
strut type front suspension design (Fig. 1).A strut assembly is used in place of the front sus-
pension upper control arm and upper ball joint.
When a vehicle strikes a bump, the force is trans-
ferred through the hub, bearing, and knuckle, into
the strut assembly to absorb the force and dampen it.
The top of the strut is mounted directly to the strut
tower of the vehicle. During steering maneuvers, the
strut assembly (through a pivot bearing in the upper
strut mount) and steering knuckle (through the lower
ball joint mounted on the lower control arm) turn as
an assembly.
PLSUSPENSION 2 - 9

(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)

(12) Remove the tie rod heat shield.
(13) Remove the nut and pinch bolt clamping the
ball joint stud to the steering knuckle (Fig. 11).
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 knuckles while removing the nuts, then tap
the bolts out using a pin punch.
(14) Remove the two bolts attaching the strut to
the steering knuckle (Fig. 1).
NOTE: Use caution when separating the ball joint
stud from the steering knuckle, so the ball joint seal
does not get cut.
(15) Separate the ball joint stud from the steering
knuckle by prying down on lower control arm and up
against the ball joint boss on the steering knuckle
(Fig. 12).
NOTE: Do not allow the driveshaft to hang by the
inner C/V joint; it must be supported to keep the
joint from separating during this operation.
(16) Pull the steering knuckle off the driveshaft
outer C/V joint splines and remove the steering
knuckle.
NOTE: The cartridge type front wheel bearing used
on this vehicle is not transferable to the replace-
ment steering knuckle. If the replacement steering
knuckle does not come with a wheel bearing, a new
bearing must be installed in the steering knuckle.
Installation of the new wheel bearing and hub mustbe done before installing the steering knuckle on
the vehicle.
(17) If the steering knuckle is to be replaced, refer
to STEERING KNUCKLE in the DISASSEMBLY
AND ASSEMBLY section in this section of this ser-
vice manual group for the wheel bearing and hub
removal and installation procedure. Do not reuse the
wheel bearing
INSTALLATION
(1) If the steering knuckle has been replaced, refer
to STEERING KNUCKLE in DISASSEMBLY AND
ASSEMBLY found in this section of this service man-
ual group for the wheel bearing and hub installation
procedure. Do not reuse the old wheel bearing.
(2) Slide the hub of the steering knuckle onto the
splines on the driveshaft C/V joint.
(3) Install the steering knuckle onto the ball joint
stud aligning the bolt hole in the knuckle boss with
the notch formed in the side of the ball joint stud.
(4) Install a new ball joint stud pinch bolt and nut
(Fig. 11). Tighten the nut to a torque of 95 N´m (70
ft. lbs.).
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.
(5) 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
Fig. 11 Ball Joint Bolt And Nut
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
Fig. 12 Separate Ball Joint from Knuckle
1 ± STEERING KNUCKLE
2±PRYBAR
3 ± LOWER CONTROL ARM
4 ± BALL JOINT STUD
PLSUSPENSION 2 - 17
REMOVAL AND INSTALLATION (Continued)

lizer bar cushion retainer bolts a little to ease any
turning resistance.
(5) Remove the nut and pinch bolt clamping the
ball joint stud to the steering knuckle (Fig. 15).
CAUTION: After removing the steering knuckle
from the ball joint stud, do not pull outward on the
knuckle. Pulling the steering knuckle outward at
this point can separate the inner C/V joint on the
driveshaft. Refer to FRONT DRIVESHAFTS in the
DIFFERENTIAL AND DRIVELINE group for further
information.
NOTE: Use caution when separating the ball joint
stud from the steering knuckle, so the ball joint seal
does not get cut.
(6) Separate the ball joint stud from the steering
knuckle by prying down on lower control arm and up
against the ball joint boss on the steering knuckle
(Fig. 12).
(7) If the right lower control arm is being serviced,
remove the bolts mounting the engine torque strut in
place (Fig. 16), then remove the engine torque strut
from the vehicle.
(8) Remove the front pivot bolt attaching the lower
control arm to the front suspension crossmember
(Fig. 17). Remove the rear pivot bolt attaching the
lower control arm to the front suspension crossmem-
ber and frame rail. Remove the lower control arm
from the crossmember.
INSTALLATION
(1) Position the lower control arm into the cross-
member (Fig. 17). Install, but do not fully tighten,
the rear pivot bolt attaching the lower control arm to
the front suspension crossmember and frame rail.
Install the front pivot bolt attaching the lower con-
trol arm to the front suspension crossmember.
(2) Tighten the lower control arm rear pivot (and
suspension crossmember) bolt to a torque of 203 N´m
(150 ft. lbs.), then tighten the lower control arm front
pivot bolt to a torque of 163 N´m (120 ft. lbs.).
(3) Install the ball joint stud into the steering
knuckle aligning the bolt hole in the knuckle boss
Fig. 15 Ball Joint Bolt And Nut
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
Fig. 16 Engine Torque Strut
1 ± MOUNTING BOLTS
2 ± ENGINE TORQUE ISOLATOR STRUT
3 ± FRONT SUSPENSION CROSSMEMBER
Fig. 17 Lower Control Arm Attaching Bolts
1 ± LOWER CONTROL ARM
2 ± FRONT BOLT
3 ± CROSSMEMBER
4 ± REAR BOLT
PLSUSPENSION 2 - 19
REMOVAL AND INSTALLATION (Continued)

with the notch formed in the side of the ball joint
stud.
(4) If the right lower control arm has been ser-
viced, install the engine torque strut (Fig. 16). Follow
the procedure described in the ENGINE service man-
ual group to properly align and tighten the torque
strut.
(5) Install a new ball joint stud pinch bolt and nut
(Fig. 15). Tighten the nut to a torque of 95 N´m (70
ft. lbs.).
(6) Rotate the forward ends of the stabilizer bar
into mounting position.
(7) Install both stabilizer bar links back on vehicle
(Fig. 14). Start each stabilizer bar link bolt with
bushing from the bottom, through the stabilizer bar,
inner link bushings, lower control arm, and into the
upper retainer/nut and bushing (Fig. 1). Do not fully
tighten the link assemblies at this time.
(8) Lower the vehicle to ground level.
NOTE: It may be necessary to put the vehicle on a
platform hoist or alignment rack to gain access to
the stabilizer bar mounting bolts with the vehicle at
curb height.
(9) Tighten each stabilizer bar link by holding the
upper retainer/nut with a wrench and turning the
link bolt. Tighten each link bolt to a torque of 23
N´m (200 in. lbs.).
(10) If previously loosened, tighten the stabilizer
bar cushion retainer bolts to a torque of 28 N´m (250
in. lbs.).
STABILIZER BAR (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 both stabilizer bar links from the vehi-
cle (Fig. 18). Remove each link by holding the upper
retainer/nut with a wrench and turning the link bolt.
(3) Remove the stabilizer bar cushion retainer
bolts and retainers (Fig. 18), and remove the stabi-
lizer bar with cushions attached from the vehicle.
(4) To remove the cushions from the stabilizer bar,
peel back each cushion at the slit and roll it off the
bar.
INSTALLATION
NOTE: Before stabilizer bar installation, inspect the
cushions and links for excessive wear, cracks, dam-
age and distortion. Replace any pieces failing
inspection.
(1) If removed, install the stabilizer bar cushions
on the stabilizer bar utilizing the slit in each cush-
ion. Position the cushions at each end of the bar's
straight beam, just before it begins to curve.
NOTE: Before installing the stabilizer bar, make
sure the bar is not upside-down. The stabilizer bar
must be installed with the curve on the outboard
ends of the bar facing downward to clear the con-
trol arms once fully installed (Fig. 19).
(2) First, place the stabilizer bar in position on the
front suspension crossmember. The slits in each
cushion must point toward the front of the vehicle
and sit directly on top of the raised beads formed
into the stamping on the crossmember. Next, install
the cushion retainers, matching the raised beads
formed into the cushion retainers to the grooves
formed into the cushions. Install the cushion retainer
bolts, but do not completely tighten them at this
time.
(3) Install both stabilizer bar links back on vehicle
(Fig. 18). Start each stabilizer bar link bolt with
bushing from the bottom, through the stabilizer bar,
inner link bushings, lower control arm, and into the
upper retainer/nut and bushing (Fig. 1). Do not fully
tighten the link assemblies at this time.
Fig. 18 Stabilizer Bar
1 ± STABLILIZER BAR CUSION RETAINERS
2 ± CUSHIONS
3 ± FRONT STABLIZER BAR
4 ± STABILIZER BAR LINKS
2 - 20 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)