Neon, 2000 - 2005

Vehicles With 2.0L Engines

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. With the vehicle on the ground and brakes applied, loosen, but do not remove the stub axle-to-hub and bearing retaining nut.
    NOTE
    The front hub and halfshaft are splined together and retained by the hub nut.

  4.  
  5. If equipped with Anti-lock Brake System (ABS), disconnect the front wheel speed sensor.
  6.  
  7. Remove or disconnect the following:

    Front wheel
     
    Front caliper-to-steering knuckle bolts
     
    Caliper from the steering knuckle
     

  8.  
  9. Support the caliper out of the way by suspending it with a piece of wire from the strut. DO NOT allow the caliper to hang by the brake hose.
    WARNING
    Be careful when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get damaged.



    Rotor from the hub
     
    Outer tie rod end-to-steering knuckle nut by holding the tie rod end stud with a 11 / 32 inch socket while loosening the nut
     
    Tie rod end stud from the steering knuckle
     
    Ball joint stud-to-steering knuckle nut and bolt
     



    Ball joint stud from the steering knuckle by prying down on the lower control arm
     

  10.  
  11. For 2000 vehicles, perform the following steps:
    1. Remove the hub and bearing-to-stub axle retaining nut.
    2.  
    3. Install a puller on the hub and bearing assembly, using the lug nuts to hold it in place.
    4.  
    5. Install a wheel lug nut on wheel stud to protect the threads on the stud. Install a flat-bladed pry tool to keep the hub from turning. Using the puller, force the outer stub axle from the hub and bearing.
      WARNING
      Be careful when separating the inner CV-joint during this operation. Do not let the halfshaft hang by the inner CV-joint, the halfshaft must be supported.

    6.  

  12.  
  13. Pull the steering knuckle assembly out and away from the outer CV-joint of the halfshaft assembly. Support the outer end of the halfshaft assembly.
  14.  
  15. Insert a pry bar between the inner tripod joint and the transaxle case. Pry against the inner tripod joint until the joint retaining snap ring is disengaged from the transaxle side gear.
    NOTE
    Inner tripod joint removal is easier by applying outward pressure on the joint while hitting the punch with a hammer.

  16.  
  17. Remove the inner tripod joints from the transaxle side gears using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Hit the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Hit the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear.
  18.  
  19. Hold the inner tripod joint and interconnecting shaft of the halfshaft assembly. Remove the inner tripod joint from the transaxle by pulling it straight out of the transaxle side gear and transaxle oil seal. When removing the tripod joint, do not let the spline or snap ring drag across the sealing lip of the transaxle-to-tripod joint oil seal.
    WARNING
    The halfshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to be supported or moved on its wheels with a halfshaft removed, install a proper-sized bolt and nut through the front hub. Tighten the bolt and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.

  20.  

To install:

  1. Thoroughly clean the spline and oil seal sealing surface on the tripod joint. Lightly lubricate the oil seal sealing surface on the tripod joint with fresh, clean transmission fluid.
  2.  
  3. Holding the halfshaft assembly by the tripod joint and interconnecting shaft, install the tripod joint into the transaxle side gear as far as possible by hand.
  4.  
  5. Carefully align the tripod joint with the transaxle side gears. Then, grasp the halfshaft interconnecting shaft and push the tripod joint into the transaxle side gear until fully seated. Be sure the snap ring is fully engaged with the side gear by trying to remove the tripod joint from the transaxle by hand. If the snap ring is fully seated with the side gear, the tripod joint will not be removable by hand.
  6.  
  7. Clean all debris and moisture out of the steering knuckle.
  8.  
  9. Be sure that the outer CV-joint, which fits into the steering knuckle, has no debris or moisture on it before installing into the steering knuckle.
  10.  
  11. Slide the halfshaft back into the front hub. Install the steering knuckle into the ball joint stud.
  12.  
  13. Install a NEW steering knuckle-to-ball joint stud bolt and nut. Tighten the nut and bolt to 70 ft. lbs. (95 Nm).
  14.  
  15. Insert the tie rod end into the steering knuckle. Start the tie rod end-to-steering knuckle nut onto the stud of the tie rod end. While holding the stud of the tie rod end stationary, tighten the nut. Then, using a crow-s foot and 11 / 32 in socket, tighten the tie rod end nut to 45 ft. lbs. (61 Nm).
  16.  
  17. Install the rotor back onto the hub and bearing assembly.
  18.  
  19. Position the caliper on the steering knuckle. Slide the top of the caliper under the top abutment on the steering knuckle, then install the bottom of the caliper against the bottom abutment of the steering knuckle.
  20.  
  21. Install the caliper-to-knuckle bolts and tighten to 23 ft. lbs. (31 Nm).
  22.  
  23. On vehicles equipped with ABS, connect the front wheel speed sensor.
  24.  
  25. Clean all foreign matter from the threads of the outer CV-joint stub axle. Install hub nut and washer onto the threads of the stub axle and tighten the nut.
  26.  
  27. With the vehicle-s brakes applied to prevent the axle shaft from turning, tighten the hub nut to 180 ft. lbs. (244 Nm).
  28.  
  29. Install the front wheel and tire assembly. Install the lug nuts and tighten to 100 ft. lbs. (135 Nm).
  30.  
  31. Check the transaxle fluid level, lowering the vehicle as necessary.
  32.  

 
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