DODGE NEON 1999 Service Manual Online

(10) Install the driveshaft requiring boot replace-
ment back on the vehicle. See Servicing Driveshaft in
this section for the required driveshaft installation
procedure.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Caliper To Knuckle Bolt........31N´m(23ft.lbs.)
Driveshaft Nut.............183 N´m (135 ft. lbs.)
Front Wheel Lug Nuts.......135 N´m (100 ft. lbs.)
Knuckle To Ball Joint Bolt......95N´m(70ft.lbs.)
Tie Rod End To Knuckle........61N´m(45ft.lbs.)
SPECIAL TOOLS
DRIVESHAFT
Fig. 49 Sealing Boot Retaining Clamp Installed
Tie Rod Remover MB-990635
Boot Clamp Installer C-4975A
3 - 16 DIFFERENTIAL AND DRIVELINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

BRAKES
CONTENTS
page page
ANTILOCK BRAKE SYSTEM±TEVES MARK 20 . 69
BASE BRAKE SYSTEM..................... 2GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page
GENERAL INFORMATION
BASE BRAKE SYSTEM DESCRIPTION........ 1
GENERAL INFORMATION
BASE BRAKE SYSTEM DESCRIPTION
Typical brake equipment consists of:
²Double pin floating caliper disc front brakes.
²Rear automatic adjusting drum brakes.
²Brake Fluid Level Switch.
²Master cylinder.
²Vacuum power booster.
²Double pin floating caliper rear disc brakes are
available on some models.
²Hand operated auto adjust park brake lever.
²Front disc brake pads are semi-metallic.
Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20 and
is supplied by Teves. This system shares the base
brake hardware with vehicles not equipped withABS. A vehicle equipped with ABS does however use
a different vacuum booster, master cylinder and
brake tubes. Also included in the ABS system is an
integrated control unit (ICU), four wheel speed sen-
sors, and an electronic controller referred to as the
controller antilock brakes (CAB). These components
will be described in detail in the Teves Mark 20 ABS
brake section in this group of the service manual.
The hydraulic brake system is diagonally split on
both the Non-ABS and ABS braking system. With the
left front and right rear brakes on one hydraulic sys-
tem and the right front and left rear on the other.
The master cylinder is anodized, lightweight alu-
minum. On vehicles equipped with front disc brakes
and rear drum brakes, the master cylinder bore is
21.0 mm. On vehicles equipped with four wheel disc
brakes, the master cylinder bore is 22.2 mm.
PLBRAKES 5 - 1

BASE BRAKE SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES.............. 6
FRONT DISC BRAKES..................... 2
MASTER CYLINDER...................... 6
PARKING BRAKES........................ 4
PROPORTIONING VALVES................. 5
REAR DISC BRAKES...................... 4
REAR DRUM BRAKES..................... 4
REAR WHEEL HUB/BEARING............... 8
RED BRAKE WARNING LAMP............... 7
STOP LAMP SWITCH...................... 8
VACUUM BOOSTER...................... 6
DIAGNOSIS AND TESTING
BRAKE FLUID CONTAMINATION............ 19
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE.... 9
BRAKE SYSTEM DIAGNOSIS CHARTS....... 10
DRUM BRAKE AUTOMATIC ADJUSTER....... 14
PROPORTIONING VALVES................ 16
RED BRAKE WARNING LAMP TEST......... 19
ROTOR THICKNESS AND RUNOUT.......... 14
STOP LAMP SWITCH TEST PROCEDURE..... 19
SERVICE PROCEDURES
BRAKE BLEEDING....................... 20
BRAKE DRUM MACHINING................ 23
BRAKE FLUID LEVEL CHECK.............. 19
BRAKE ROTOR MACHINING............... 22
BRAKE TUBE REPAIR.................... 25
MASTER CYLINDER BLEEDING............ 21
PARK BRAKE LEVER AUTO ADJUSTER
MECHANISM.......................... 23
REMOVAL AND INSTALLATION
CHASSIS TUBES AND HOSES.............. 47
FRONT DISC BRAKE CALIPER............. 26
FRONT DISC BRAKE SHOES.............. 28
MASTER CYLINDER..................... 41
PARK BRAKE CABLES.................... 50
PARK BRAKE LEVER ASSEMBLY........... 48PARK BRAKE LEVER OUTPUT CABLE....... 49
PARK BRAKE SHOES WITH REAR DISC
BRAKES............................. 55
PROPORTIONING VALVE (BASE BRAKES).... 47
REAR BRAKE DRUM..................... 34
REAR BRAKE SHOE SUPPORT PLATE....... 37
REAR BRAKE SHOES.................... 35
REAR BRAKE WHEEL CYLINDER........... 38
REAR DISC BRAKE CALIPER.............. 30
REAR DISC BRAKE SHOES................ 32
REAR HUB/BEARING..................... 39
STOP LAMP SWITCH..................... 57
VACUUM BOOSTER..................... 44
WHEEL AND TIRE ASSEMBLY.............. 26
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID LEVEL SWITCH............. 58
BRAKE FLUID RESERVOIR................ 57
FRONT AND REAR DISC BRAKE CALIPER.... 58
WHEEL CYLINDER (REAR DRUM BRAKE).... 63
CLEANING AND INSPECTION
CHASSIS TUBES AND HOSES.............. 65
FRONT DISC BRAKES.................... 63
REAR DISC BRAKES..................... 64
REAR DRUM BRAKE WHEEL CYLINDER...... 65
REAR DRUM BRAKES.................... 64
REAR WHEEL HUB AND BEARING ASSEMBLY . 65
ADJUSTMENTS
PARK BRAKE ADJUSTMENT............... 66
REAR DRUM BRAKE SHOE ADJUSTMENT.... 65
STOP LAMP SWITCH..................... 65
SPECIFICATIONS
BRAKE ACTUATION SYSTEM.............. 67
BRAKE FASTENER TORQUE SPECIFICATIONS . 67
BRAKE FLUID.......................... 67
SPECIAL TOOLS
BASE BRAKE SYSTEM................... 68
DESCRIPTION AND OPERATION
FRONT DISC BRAKES
The front disc brakes (Fig. 1) and (Fig. 2) consists
of the following components:
²The driving hub
²Braking disc (rotor)
²Caliper assembly - single piston, floating type
²Brake shoes and linings
The double pin calipers are mounted directly to the
steering knuckles and use no adapter. The caliper ismounted to the steering knuckle using bushings,
sleeves and 2 guide pin bolts which thread directly
into bosses on the steering knuckle (Fig. 2) and (Fig.
3).
Two machined abutments on the steering knuckle
position the caliper. The guide pin bolts, sleeves and
bushings control the side to side movement of the
caliper. The piston seal is designed to pull the piston
back into the bore of the caliper when the brake
pedal is released. This maintains the proper brake
shoe to rotor clearance (Fig. 4).
5 - 2 BRAKESPL

All the front brake forces generated during braking
of the vehicle is taken up directly by the steering
knuckles of the vehicle.
The caliper is a one piece casting with the inboard
side containing a single piston cylinder bore.
The front disc brake caliper piston (Fig. 2), is man-
ufactured from a phenolic compound. The outside
diameter of the caliper piston is 54 mm.
A square cut rubber piston seal is located in a
machined groove in the caliper cylinder bore. This
provides a hydraulic seal between the piston and the
cylinder wall (Fig. 4).
A rubber dust boot is installed in the cylinder bore
opening and in a groove in the piston (Fig. 4). This
prevents contamination in the bore area.As front disc brake linings wear, master cylinder
reservoir brake fluid level will drop. Fluid level
should be checked after replacing linings.
Front disc brakes are equipped with an audible
wear indicator (Fig. 2) on the outboard brake pad.
This sensor emits a sound when the brake lining
may need inspection and/or replacement.
Fig. 1 Front Disc Brake Caliper Assembly
Fig. 2 Front Disc Brake Caliper (Exploded View)
Fig. 3 Front Disc Brake Caliper Mounting
PLBRAKES 5 - 3
DESCRIPTION AND OPERATION (Continued)

REAR DISC BRAKES
The rear disc brakes are similar to the front disc
brakes, however, there are several distinctive fea-
tures that require different service procedures. The
single piston, floating caliper rear disc brake assem-
bly includes a hub and bearing assembly, adapter,
brake rotor, caliper, brake pads/linings. The parking
brake system on all vehicles equipped with rear disc
brakes consists of a small duo-servo drum brake
mounted to the caliper adapter. The drum brake
shoes expand out against a braking surface (hat sec-
tion) on the inside area of the rotor.
Vehicles are equipped with a caliper assembly that
has a 34 mm (1.43 in.) piston and uses a solid non-
vented rotor.
The caliper assembly on all applications float on
rubber bushings using internal metal sleeves which
are attached to the adapter using threaded guide pin
bolts.
The adapter and rotor shield are mounted to the
rear suspension knuckles of vehicle. The adapter is
used to mount the brake shoes and actuating cables
for the parking brake system. The adapter also
mounts the rear caliper assembly to the vehicle. The
adapter has two machined abutments which are used
to position and align the caliper and brake pads for
movement inboard and outboard (Fig. 5).
REAR DRUM BRAKES
The rear wheel drum brakes are a two shoe, inter-
nal expanding type with an automatic adjuster screw
(Fig. 6). The automatic adjuster screw is actuated
each time the brakes are applied. The automatic
adjuster screw is located directly below the rear
brake wheel cylinder.
PARKING BRAKES
All vehicles are equipped with a center mounted,
hand operated park brake lever. This lever is an
auto-adjust type which continuously applies minimal
tension to the parking brake cables to keep them in
adjustment at all times. Due to this feature, the parkbrake cable system does not require adjustment.
Proper parking brake system adjustment is obtained
by proper drum brake or drum-in-hat brake shoe
adjustment.
On vehicles equipped with rear drum brakes, the
rear wheel service brakes also act as the vehicle's
parking brakes. The rear drum brake shoes, when
acting as parking brakes, are mechanically operated
using an internal actuating lever and strut which is
connected to a flexible steel cable. There is an indi-
vidual park brake cable for each rear wheel, which
are joined using a park cable equalizer before termi-
nating at the floor mounted, hand operated park
brake lever.
The parking brakes on vehicles equipped with rear
disc brakes consist of a small duo-servo brake assem-
bly mounted to the disc brake caliper adapter (Fig.
7). The hat (center) section (Fig. 8) of the rear rotor
serves as the braking surface (drum) for the parking
brakes. This park brake application uses the same
Fig. 4 Piston Seal Function for Automatic
Adjustment
Fig. 5 Rear Disc Brake Assembly Exploded View
Fig. 6 Kelsey Hayes Rear Wheel Brake Assembly
(Left Side Shown)
5 - 4 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

operating cable configuration as the drum brake
equipped vehicles, but different cables.
PROPORTIONING VALVES
NON-ANTILOCK BRAKES
Proportioning valves balance front to rear braking
by controlling at a given ratio, the increase in rear
brake system hydraulic pressure above a preset level
(split point). Under light pedal application, the pro-portioning valve allows full hydraulic pressure to be
applied to the rear brakes.
The non-antilock master cylinder is a four outlet
design with two screw-in proportioning valves (Fig.
9) attached directly to the inboard side of the master
cylinder housing.
There are two proportioning valve assemblies used
in each vehicle. Due to differences in thread sizes,
each proportioning valve has a different part number.
During any service procedures identify valve assem-
blies by supplier part number and or the color iden-
tification band (Fig. 10).
ANTILOCK BRAKES PROPORTIONING VALVES
The master cylinder on vehicles equipped with
antilock brakes is a two outlet design. This antilock
brakes master cylinder does not have the proportion-
ing valves mounted on it.
On vehicles equipped with antilock brakes the pro-
portioning valves are located at the rear of the vehi-
cle (Fig. 11). The proportioning valves are mounted
directly in-line with the chassis brake tube going to
each rear brake of the vehicle (Fig. 11).
There are two proportioning valves used in each
vehicle. Due to differences in thread sizes, each pro-
Fig. 7 Park Brake Assembly With Rear Disc Brakes
Fig. 8 Drum In Hat Rotor
Fig. 9 Master Cylinder And Proportioning Valves For
Non Antilock Equipped Vehicles
Fig. 10 Non-Antilock Proportioning Valve
PLBRAKES 5 - 5
DESCRIPTION AND OPERATION (Continued)

portioning valve has a different part number. During
any service procedures identify valve assemblies by
supplier part number and or the color identification
band (Fig. 12).
CHASSIS TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The chassis tubes are steel with a corro-
sion resistant coating applied to the external surfaces
and the flex hoses are made of reinforced rubber. The
rubber flex hoses allow for the movement of the vehi-
cles suspension.
MASTER CYLINDER
This vehicle is available with three different mas-
ter cylinders. The vehicle uses screw-in proportioning
valves at the master cylinder or in-line proportioning
valves located in the rear chassis brake tubes instead
of a combination valve. With this new design, the
chassis brake tubes connect directly from the master
cylinder or HCU to the front and rear brake flex
hoses.
Vehicles not equipped with ABS use a standard
compensating port master cylinder, while vehicles
equipped with ABS use a center valve design mastercylinder. In addition, the non-ABS master cylinders
are a four outlet design with two screw-in proportion-
ing valves attached directly to the inboard side of the
master cylinder housing (Fig. 13). The ABS master
cylinder is a two outlet design (Fig. 14). The primary
and secondary outlet on the master cylinder are con-
nected directly to the hydraulic control portion of the
ICU (Fig. 14) Vehicles equipped with antilock brakes
use in-line proportioning valves mounted in the chas-
sis brake tubes going to the rear brakes. Vehicles
equipped with rear drum brakes use a master cylin-
der with a 21.0 mm bore diameter, while vehicles
equipped with rear disc brake use a 22.2 mm bore
master cylinder.
The master cylinder (Fig. 13) consists of the follow-
ing components. The body of the master cylinder is
an anodized aluminum casting. It has a machined
bore to accept the master cylinder piston and
threaded ports with seats for hydraulic brake line
connections. The brake fluid reservoir of the master
cylinder assembly is made of a see through type plas-
tic.
On Non-ABS master cylinders, the primary outlet
ports (Fig. 15) supply hydraulic pressure to the left
front and right rear brakes. The secondary outlet
ports (Fig. 15) supply hydraulic pressure to the right
front and left rear brakes.
On the ABS master cylinder, the primary outlet
port (Fig. 14) supplies hydraulic pressure to the right
front and left rear brakes. The secondary outlet port
(Fig. 14) supplies hydraulic pressure to the left front
and right rear brakes.
VACUUM BOOSTER
All vehicles use a 230 mm single diaphragm power
brake vacuum booster. There are however two differ-
ent booster designs; one for vehicles equipped with
ABS and one for vehicles without ABS. These two
Fig. 11 Antilock Proportioning Valve (Left Side
Shown)
Fig. 12 Antilock Proportioning Valve
Fig. 13 Master Cylinder For Non Antilock Brake
Equipped Vehicles
5 - 6 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

boosters differ at the interface to the master cylinder.
If the power brake booster requires replacement be
sure it is replaced with the correct part.
The power brake booster can be identified by the
tag attached to the body of the booster assembly (Fig.
16). This tag contains the following information: The
production part number of the power booster assem-
bly, the date it was built, who manufactured it, and
brake sales code.
NOTE: The power brake booster assembly is not a
repairable part and must be replaced as a complete
unit if it is found to be faulty in any way. The power
booster vacuum check valve is not repairable but
can be replaced as an assembly.The power brake booster reduces the amount of
force required by the driver to obtain the necessary
hydraulic pressure to stop vehicle.
The power brake booster is vacuum operated. The
vacuum is supplied from the intake manifold on the
engine through the power brake booster check valve
(Fig. 16).
As the brake pedal is depressed, the power booster
input rod moves forward (Fig. 17). This opens and
closes valves in the power booster, allowing atmo-
spheric pressure to enter on one side of a diaphragm.
Engine vacuum is always present on the other side.
This difference in pressure forces the output rod of
the power booster (Fig. 17) out against the primary
piston of the master cylinder. As the pistons in the
master cylinder move forward this creates the
hydraulic pressure in the brake system.
Different engine options available for this vehicle
require that different vacuum hose routings be used.
The power brake vacuum booster assembly mounts
on the engine side of the dash panel. It is connected
to the brake pedal by the input push rod (Fig. 17). A
vacuum line connects the power booster to the intake
manifold. The master cylinder is bolted to the front
of the power brake vacuum booster assembly.
RED BRAKE WARNING LAMP
The red Brake warning lamp is located in the
instrument panel cluster and is used to indicate a
low brake fluid condition or that the parking brake is
applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch
when the ignition switch is placed in the crank posi-
tion. Problems with this system will generally be of
the type where the warning lamp fails to turn on
when it should, or remains on when it should not.
The warning lamp bulb is supplied a 12 volt igni-
tion feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit
Fig. 14 Master Cylinder For Antilock Brake
Equipped Vehicles
Fig. 15 Non-ABS Master Cylinder Primary And
Secondary Ports
Fig. 16 Power Brake Booster Identification
PLBRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)

either through the park brake switch, the fluid level
sensor in the master cylinder reservoir, or the igni-
tion switch in the crank position.
The Brake Fluid Level sensor is located in the
brake fluid reservoir of the master cylinder assembly
(Fig. 18). The purpose of the sensor is to provide the
driver with an early warning that the brake fluid
level in the master cylinder reservoir has dropped to
below normal. This may indicate an abnormal loss of
brake fluid in the master cylinder fluid reservoir
resulting from a leak in the hydraulic system.
As the fluid drops below the minimum level, the
fluid level sensor closes the brake warning light cir-
cuit. This will turn on the red brake warning light.
At this time, master cylinder fluid reservoir shouldbe checked and filled to the full mark with DOT 3
brake fluid.If brake fluid level has dropped in
master cylinder fluid reservoir, the entire
brake hydraulic system should be checked for
evidence of a leak.
STOP LAMP SWITCH
The stop lamp switch controls operation of the
vehicles stop lamps. Also, if the vehicle is equipped
with speed control, the stop lamp switch will deacti-
vate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the
right and left tail, stop and turn signal lamp and
CHMSL lamp, by supplying battery current to these
lamps.
The stop lamp switch controls the lamp operation
by opening and closing the electrical circuit to the
stop lamps.
REAR WHEEL HUB/BEARING
CAUTION: If a vehicle is equipped with antilock
brakes the tone wheels for the rear wheel speed
sensors are pressed onto the hub. The tone wheels
used on this vehicle equipped with the Teves Mark
20 Antilock Brake System are different then those
used on past models of this vehicle equipped with
antilock brakes. Reduced braking performance will
result if this part is used on earlier model vehicles
and an accident could result. Do not use on
pre-1998 model year vehicles.
All vehicles are equipped with permanently lubri-
cated and sealed for life rear wheel bearings. There
is no periodic lubrication or maintenance recom-
mended for these units. However, if servicing of a
rear wheel bearing is required, refer to procedures in
the diagnosis and testing section and the removal
and installation section in this group of the service
manual for the inspection and replacement of the
rear wheel bearing.Fig. 17 Power Brake Booster Assembly
Fig. 18 Master Cylinder Fluid Level Sensor
5 - 8 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
SYMPTOMCHART 1
MISC.
COND.CHART 2
WARNING
LIGHTCHART 3
POWER
BRAKESCHART 4
BRAKE
NOISECHART 5
WHEEL
BRAKES
Brake Warning Light On X NO NO
Excessive Pedal Travel 6 X NO O
Pedal Goes To The Floor 6 X
Stop Light On Without Brakes 3
All Brakes Drag 5
Rear Brakes Drag 2 NO NO
Grabby Brakes O X
Spongy Brake Pedal X NO
Premature Rear Brake Lockup 4 NO NO O
Excessive Pedal Effort 1 O
Rough Engine Idle NO O
Brake Chatter (Rough) NO NO X
Surge During Braking NO NO X
Noise During Braking NO NO X
Rattle Or Clunking Noise NO NO X
Pedal Pulsates During Braking NO NO X
Pull To Right Or Left NO NO X
No: Not A Possible Cause X: Most Likely Cause O: Possible Cause
PLBRAKES 5 - 9