Neon, 2000 - 2005

Vehicles With 2.4L Engines

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. 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.

  6.  
  7. If equipped with Anti-lock Brake System (ABS), disconnect the front wheel speed sensor.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Be careful when separating the ball joint stud from the steering knuckle to prevent damaging the components.


    WARNING
    Be careful not to separate the inner CV-joint during this operation. Do not let the halfshafthang by inner CV-joint, it MUST be supported.


    NOTE
    If you are encountering difficulty separating the halfshaft from the hub, use puller 1026, DO NOT hit the shaft with a hammer.



    Front wheel
     
    Cotter pin, nut lock, and spring washer, and hub nut from the end of the outer CV-joint stub axle
     
    Front wheel speed sensor and secure harness out of the way, if equipped with Anti-lock Brake System (ABS)
     
    Nut and bolt securing the ball joint stud into steering knuckle
     



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



    Halfshaft from the steering knuckle by pulling outward on knuckle while pressing in on the halfshaft. Support the outer end of halfshaft assembly.
     

  10.  
  11. Support the outer end of the halfshaft assembly.
    NOTE
    When the left halfshaft is removed from transaxle, some fluid may leak out.


    NOTE
    It is easier to remove the inner tripod joint if you apply outward pressure on the joint as you strike the punch with a hammer. Do not pull on the interconnecting shaft to remove, as the inner joint will become separated.

  12.  
  13. Remove or disconnect the following:

    Left halfshaft by applying outward pressure on joint by hand, dislodge the inner tripod joint from the differential side gear by striking outward with a punch. When removing the tripod joint and halfshaft, do not let the spline or snap ring drag across axle seal.
     
    Right halfshaft by sliding the inner tripod joint off the intermediate shaft. If necessary, use a punch to dislodge the joint from the intermediate shaft.
     
    Intermediate shaft, if necessary, by removing the 2 intermediate shaft bearing-to-bracket bolts

    Click image to see an enlarged view

    Fig. Exploded view of the halfshaft assemblies-2.4L engines

     

  14.  

To install:


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.

  1. Install or connect the following:

    Intermediate shaft/bearing, if removed. Torque the bearing-to-bracket bolts to 40 ft. lbs. (54 Nm).
     

  2.  
  3. On the left halfshaft, thoroughly clean the spline and oil seal sealing surface on the left tripod joint. Lightly lubricate the oil seal sealing surface on the tripod joint with fresh, clean transmission fluid.
  4.  
  5. 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.
  6.  
  7. 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.
  8.  
  9. On the right halfshaft, thoroughly clean the right halfshaft tripod joint spline, and the intermediate shaft spline. While holding the halfshaft assembly by the tripod joint and interconnecting shaft, install tripod joint onto the intermediate shaft as far as possible by hand.
  10.  
  11. Slide the halfshaft back into front hub. Install the steering knuckle onto the ball joint stud
    NOTE
    At this point, the outer joint will not seat completely into the front hub. The outer joint will bepulled into hub and seated when the hub nut is installed and torqued.

  12.  
  13. Install or connect the following:

    New steering knuckle-to-ball joint stud bolt and nut. Tighten to 70 ft. lbs. (95 Nm).
     

  14.  
  15. On vehicles equipped with ABS, connect the front wheel speed sensor.
  16.  
  17. 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.
  18.  
  19. With the vehicle-s brakes applied to prevent the axle shaft from turning, tighten the hub nut to 180 ft. lbs. (244 Nm).

    Spring washer, nut lock, and cotter pin
     

  20.  
  21. Install the front wheel and tire assembly. Install the lug nuts and tighten to 100 ft. lbs. (135 Nm).
  22.  
  23. Check the transaxle fluid level, lowering the vehicle as necessary.
  24.  

 
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