Dodge Neon / Neon SRT-4. Manual - part 279

(13) Using an awl, scribe a line (Fig. 18) marking

the location of where the front suspension crossmem-
ber is mounted against the body of the vehicle.

(14) Position a transmission jack under the center

of the front suspension crossmember and raise it to
support the bottom of the crossmember.

(15) Loosen and completely remove the two front

bolts (one right and one left) attaching the front sus-
pension crossmember to the frame rails of vehicle.
The right side bolt can be viewed in the mounting
bolt figure (Fig. 19). The left side bolt is located in
the same location on the other side of the vehicle.

(16) Loosen the two rear bolts (one right and one

left) attaching the front suspension crossmember and

lower control arms to the body of the vehicle until
they release from the threaded tapping plates in the
body of the vehicle. Remove the rear bolts from the
body of the vehicle, but do not completely remove the
rear bolts because they are designed to disengage
from the body threads yet stay within the lower con-
trol arm rear isolator bushing. This allows the lower
control arm to stay in place on the crossmember. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 19). The left side bolt is located in the
same location on the other side of the vehicle.

(17) Lower the front suspension crossmember.
(18) Remove each lower control arm from the

crossmember by removing the front pivot bolt.

INSTALLATION

CAUTION: If the front suspension crossmember is
being replaced due to collision damage, inspect the
steering column lower coupling for damage. Refer
to COLUMN in STEERING.

(1) Install the lower control arms on the front sus-

pension crossmember. Install the pivot bolts, but do
not completely tighten them at this time.

(2) Using the transmission jack, raise the front

suspension crossmember and lower control arms
until the crossmember contacts its mounting spot
against the body and frame rails of the vehicle. As
the crossmember is raised, carefully guide the power
steering gear into mounting position.

(3) Start the two rear crossmember mounting bolts

into the tapping plates mounted in the body. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 19). The left side bolt is located in the
same location on the other side of the vehicle. Next,

Fig. 17 Strut Mounting

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
5 - LOWER TORQUE STRUT

Fig. 18 Marking Crossmember Location

1 - SCRIBED LINE
2 - FRONT SUSPENSION CROSSMEMBER
3 - AWL
4 - BODY

Fig. 19 Mounting Bolts

1 - FRONT SUSPENSION CROSSMEMBER MOUNTING BOLTS
2 - ENGINE TORQUE ISOLATOR STRUT MOUNTING BOLT
3 - FRONT SUSPENSION CROSSMEMBER

13 - 14

FRAME & BUMPERS

PL/SRT-4

FRONT CROSSMEMBER (Continued)

install the two front mounting bolts attaching front
suspension crossmember to frame rails of vehicle.
Lightly tighten all four mounting bolts to a approxi-
mately 2 N·m (20 in. lbs.) to hold the front suspen-
sion crossmember in position.

NOTE:

When

reinstalling

the

front

suspension

crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle’s wheel alignment settings
(caster and camber) will be lost.

(4) Using a soft face hammer, tap the front suspen-

sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 18). Once the
front suspension crossmember is correctly positioned,
tighten the rear two crossmember mounting bolts to
a torque of 203 N·m (150 ft. lbs.), then tighten the
front two crossmember mounting bolts to a torque of
142 N·m (105 ft. lbs.).

(5) Tighten the lower control arm front pivot bolts

to a torque of 163 N·m (120 ft. lbs.).

(6) Attach the steering gear to the front suspen-

sion crossmember (Fig. 16). Install the four power
steering gear mounting bolts. Tighten the mounting
bolts to a torque of 61 N·m (45 ft. lbs.).

(7) Remove the wire or cord suspending the power

steering gear to the underbody.

(8) Install the two screws securing the cooler to

the front suspension crossmember. They are located
behind the cooler.

(9) Install each ball joint stud into the steering

knuckle aligning the bolt hole in the knuckle boss
with the notch formed in the side of the ball joint
stud.

(10) Install a new ball joint stud pinch bolt and

nut (Fig. 14). Tighten the nut to a torque of 95 N·m
(70 ft. lbs.).

(11) Install the engine torque strut and mounting

bolts (Fig. 17). To properly align and tighten the
torque

strut,

(Refer

ENGINE/ENGINE

MOUNTING/TORQUE STRUT - ADJUSTMENTS).

(12) Install the washer on the end of the stud

extending from the torque strut bolt (Fig. 17).

(13) Install the pencil strut to the right front cor-

ner of the crossmember and body of the vehicle (Fig.
17). Tighten the pencil strut nuts to a torque of 58
N·m (43 ft. lbs.).

(14) Install the drive-belt splash shield and fasten-

ers.

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. 20).

(15) 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.

(16) Install both stabilizer bar links back on vehi-

cle (Fig. 13). 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. Do not fully tighten
the link assemblies at this time.

(17) Install the tire and wheel assemblies back on

vehicle. Tighten the wheel mounting nuts to 135 N·m
(100 ft. lbs.) torque.

(18) Lower the vehicle.

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.

Fig. 20 Downward Curve

1 - STABILIZER BAR
2 - LINK
3 - DOWNWARD CURVE
4 - CUSHION RETAINER

PL/SRT-4

FRAME & BUMPERS

13 - 15

FRONT CROSSMEMBER (Continued)