Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Neon 1997.1999.2000.2004 Approved Dodge Neon 1997 EPL_2
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PL SUSPENSION 2-1
SUSPENSION
CONTENTS
page page
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 9 WHEEL ALIGNMENT ..................... 1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 36
WHEEL ALIGNMENT
INDEX
page page
DESCRIPTION AND OPERATION SERVICE PROCEDURES
WHEEL ALIGNMENT GENERAL INFORMATION WHEEL ALIGNMENT CHECK AND
....................................... 1 ADJUSTMENT PROCEDURE . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING SPECIFICATIONS
PRE-ALIGNMENT VEHICLE INSPECTION . . . . . 4 VEHICLE ALIGNMENT SPECIFICATIONS AT
SUSPENSION AND STEERING DIAGNOSIS . . . 3 CURB HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION cations recommended by Chrysler Corporation
MUST ALWAYS be used.
WHEEL ALIGNMENT GENERAL INFORMATION
Proper vehicle wheel alignment is the proper CAUTION: Do not attempt to modify any suspen-
adjustment of all interrelated front and rear suspen- sion or steering components by heating or bending
sion angles (Fig. 1). These angles are what affects of the component.
the handling and steering of the vehicle when it is in
Wheel alignment adjustments should be made in
motion.
the following sequence, to ensure that an accurate
The method of checking a vehicle's front and rear
alignment is performed.
wheel alignment will vary depending on the type and
(1) Rear Wheel Toe Adjustment within specifica-
manufacturer of the equipment being used. Instruc-
tions for both total toe and thrust angle.
tions furnished by the manufacturer of the equip-
(2) Front Wheel Toe Adjustment within specifica-
ment being used should always be followed to ensure
tions for total toe.
accuracy of the alignment, except alignment specifi-
2-2 SUSPENSION PL
DESCRIPTION AND OPERATION (Continued)
(3) Toe is measured in degrees or inches and is (4) Thrust Angle is defined as the average of the
the distance that the front edges of the tires are Toe settings on each rear wheel. If this measurement
closer (or farther apart) than the rear edges (Fig. 1). is out of specification, re-adjust rear wheel Toe so
See Front Wheel Drive Specifications for correct front that each wheel has 1/2 of the total Toe measure-
and rear wheel Toe specifications. ment. When re-adjusting, do not exceed the total Toe
specification.
Fig. 1 Alignment Camber/Toe
PL SUSPENSION 2-3
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Front End Whine On Turns 1. 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 1. Defective Wheel Bearing 1. Replace Wheel Bearing
Turns
2. Engine Mount Grounding 2. Check For Motor Mount Hitting
Against Frame Or Body Of Vehicle. 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 1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
Turns
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
3. Worn Or Loose Tie Rod Or Ball 3. Tighten Or Replace Tie Rod End
Joint Or Ball Joint
4. Worn Control Arm Bushing 4. Replace Control Arm Bushing
5. Loose Sway Bar Or Upper Strut 5. Tighten Sway Bar Or Upper Strut
Attachment Attachment To Specified Torque
Front End Whine With Vehicle 1. Defective Wheel Bearing 1. Replace Wheel Bearing
Going Straight At A Constant
Speed
2. Incorrect Wheel Alignment 2. Check And Reset Wheel
Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or Grinding With 1. Engine Mount Grounding 1. Reposition Engine As Required
Vehicle Going Straight At A
Constant Speed
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
Front End Whine When 1. Worn Or Defective Transaxle 1. Replace Transaxle Gears Or
Accelerating Or Decelerating Gears Or Bearings Bearings
Front End Clunk When 1. Worn Or Broken Engine Mount 1. Replace Engine Mount
Accelerating Or Decelerating
2. Worn Or Defective Transaxle 2. Replace Transaxle Gears Or
Gears Or Bearings Bearings
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 6. Tighten To Specified Torque Or
Bushing Replace Control Arm Bushing
7. Loose Crossmember Bolts 7. Tighten Crossmember Bolts To
Specified Torque
2-4 SUSPENSION PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Road Wander 1. Incorrect Tire Pressure 1. Inflate Tires To Rcommended
Pressure
2. Incorrect Front Or Rear Wheel 2. Check And Reset Front Wheel
Toe Toe
3. Worn Wheel Bearings 3. Replace Wheel Bearing
4. Worn Control Arm Bushings 4. Replace Control Arm Bushing
5. Excessive Friction In Steering 5. Replace Steering Gear
Gear
6. Excessive Friction In Steering 6. Replace Steering Coupler
Shaft Coupling
7. Excessive Friction In Strut Upper 7. Replace Strut Bearing
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 Play 1. Incorrect Steering Gear 1. Adjust Or Replace Steering Gear
Adjustment
2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends
3. Loose Steering Gear Mounting 3. Tighten Steering Gear Bolts To
Bolts The Specified Torque
4. Loose Or Worn Steering Shaft 5. Replace Steering Shaft Coupler
Coupler
Excessive Steering Effort 1. Low Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Lack Of Lubricant In Steering 2. Replace Steering Gear
Gear
3. Low Power Steering Fluid Level 3. Fill Power Steering Fluid
Reservoir To Correct Level
4. Loose Power Steering Pump Belt 4. Correctly Adjust Power Steering
Pump Drive Belt
5. Lack Of Lubricant In Steering Ball 5. Lubricate Or Replace Steering
Joints Ball Joints
6. Steering Gear Malfunction 6. Replace Steering Gear
7. Lack Of Lubricant In Steering 7. Replace Steering Coupler
Coupler
PRE-ALIGNMENT VEHICLE INSPECTION and necessary corrections must be made on those
parts which influence the steering of the vehicle.
CAUTION: If the front suspension crossmember (1) Be sure the fuel tank is full when the wheel
shows any sign of impact damage, the steering col- alignment specifications are checked and or adjusted.
umn to steering gear coupling must be inspected. A full tank of fuel weighs approximately 75 pounds,
Refer to Group 19 Steering in this service manual if the fuel tank is not full this reduction in weight
for the inspection procedure. will affect the curb height of the vehicle and the
alignment specifications.
Before any attempt is made to change or correct (2) Alignment specifications of a vehicle can be the
the wheel alignment factors, the following inspection most accurately checked and set when the passenger
PL SUSPENSION 2-5
DIAGNOSIS AND TESTING (Continued)
compartment and trunk of the vehicle are vacant If a vehicles caster is not within manufacturers
with the exception of the spare tire. People, luggage, alignment specifications, check for damaged suspen-
and any other appreciable weight will adversely sion components or body parts. This type of damage
affect the checking and setting of the camber specifi- can cause component locations to move affecting
cation. vehicle alignment. No adjustment can be made
(3) Check and if required, inflate all of the tires to for the Caster setting on this vehicle.
the recommended air pressure. All tires must be of
the same size and in good condition and have approx- CAUTION: Do not attempt to adjust the vehicles
imately the same tread wear. Note the type of Caster or Camber by heating, bending or any other
tread wear on the tire, this will aid in diagnos- modification of the suspension components.
ing problems. Refer to Group 22 Tires And
Wheels in this service manual for the tire wear (1) Correctly position vehicle on alignment rack
diagnosis. and install all required equipment on vehicle, per the
(4) Check the front tire and wheel assemblies for alignment equipment manufacturers specifications.
radial runout. (2) Center the steering wheel and lock in place
(5) Before beginning the alignment process, using a steering wheel clamp.
inspect all suspension component fasteners for loose-
NOTE: Prior to reading each alignment specifica-
ness and/or loss of specified torque.
tion, jounce the front and rear of the vehicle an
(6) Inspect the lower front ball joints and all steer-
equal number of times. Induce jounce (rear first
ing linkage for looseness and any signs of wear and
then front) by grasping center of bumper and jounc-
or damage.
ing each end of vehicle an equal number of times.
(7) Inspect the tie rod ends for looseness and any
Bumper should always be released when vehicle is
signs of wear and or damage.
at the bottom of the jounce cycle.
(8) Inspect the rubber bushings on all suspension
components for signs of wear or deterioration. If any (3) Correctly jounce vehicle and read front and
bushings show signs of wear or deterioration they rear alignment settings and compare to vehicle spec-
should be replaced prior to aligning the vehicle. ifications for Camber, Caster and Toe. See Alignment
Specifications in this group of the service manual for
SERVICE PROCEDURES required specifications. If front and rear camber
readings are within required specifications pro-
WHEEL ALIGNMENT CHECK AND ADJUSTMENT ceed to step Step 3 in the Front And Rear Toe
Setting procedure. If Camber readings are not
PROCEDURE
within specifications refer to step Step 1 in the
CASTER CAMBER following camber adjustment bolt package
Front and rear Caster and Camber settings on this installation procedure, for the front and rear
vehicle are determined at the time the vehicle is Camber adjustment procedure.
designed, by the location of the vehicle's suspension
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
components. This is called a Net Build vehicle and PROCEDURE
results in no required adjustment of Caster and
(1) If front and or rear camber readings obtained
Camber after vehicle is built or when servicing the
are not within the required specification range, a
suspension components. Thus Caster and Camber are
Mopar Service Kit is available to provide the
not normally considered an adjustable specification
required adjustment. The kit contains new bolts and
when performing an alignment on this vehicle.
nuts for the strut clevis bracket to steering knuckle
Though Caster and Camber are not adjustable they
attachment. The bolts contained in the service kit,
must be checked to ensure they meet vehicle specifi-
are slightly undersize allowing for movement
cations.
between the strut clevis bracket and steering
If front and or rear camber is found not to meet
knuckle. The movement allowed by the undersize
the vehicle alignment specifications, it can be
bolts will provide approximately 2 degrees of camber
adjusted using a Mopar Service Kit developed to
adjustment per side of vehicle. To install new bolts in
allow for camber adjustment. If a vehicle's front or
service kit follow the procedure below.
rear camber is found to be outside the specifications,
the vehicles suspension components should be
inspected for any signs of damage on bending. This
must be done before using the Mopar Service
Kit for setting camber to meet required specifi-
cation.
STRUT ASSEMBLY CLEVISLOOSEN
CLEVIS
REMOVE BRACKET
KNUCKLE STRUTBRACKETAND THIS BOLT
BOLT
REPLACE
THIS STEERING ATTACHING
STRUT CLEVIS BRACKET TO TO
KNUCKLEBRACKET
CLEVIS KNUCKLE
ATTACHING BOLTS
STEERING BOLTS
KNUCKLE
2-6 SUSPENSION PL
SERVICE PROCEDURES (Continued)
CAUTION: The Mopar Service Kit for allowing (4) Loosen lower bolt attaching strut clevis bracket
adjustment of front and rear camber are different to steering knuckle or rear knuckle ONLY enough to
for the front and rear of the vehicle. When using the allow knuckle to move in clevis bracket.
service kits be sure that the front and rear strut (5) Install bolt from service kit into the upper
attaching bolts are always used in the right location strut clevis bracket to steering knuckle or rear
on the vehicle. knuckle mounting hole.
(2) Raise front and or rear of vehicle until tires are CAUTION: Only the nuts supplied in the service
not supporting the weight of the vehicle. kits MUST be used with the service kit replacement
bolts. The original nuts will not properly secure the
CAUTION: The steering knuckle and rear knuckle strut clevis bracket to steering knuckle or rear
to strut assembly attaching bolts are serrated and knuckle.
must not be turned during removal. Remove nuts
while holding bolts stationary in the steering knuck- (6) Install nut provided in service kit on the
les. replacement bolt.
(7) Tighten upper bolt and nut from service kit
(3) Remove original upper bolt attaching the front until snug, but still allowing movement between
or rear strut clevis bracket to the steering knuckle or strut clevis bracket and knuckle.
rear knuckle (Fig. 2) or (Fig. 3). (8) Remove original lower bolt. Install bolt from
service kit into the bottom hole of the strut clevis
bracket. Install nut and snug.
(9) Lower vehicle until full weight of vehicle is
supported by the suspension and then jounce front
and rear of vehicle an equal amount of times.
(10) Adjust front and or rear camber to the pre-
ferred setting by pushing or pulling on the top of the
front or rear tire. When camber is correctly set
tighten upper and lower strut clevis bracket bolts.
Again jounce front and rear of vehicle an equal
amount of times and verify front and rear camber
setting. See Alignment Specifications in this group of
the service manual for required specifications.
(11) When vehicle is at correct camber setting
torque both front strut clevis bracket to steering
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