DODGE NEON 1999 Service Repair Manual

INSTALL
CAUTION: The hub/bearing retaining nut must be
tightened to but must not exceed its required
torque specification. The proper torque specifica-
tion of the retaining nut is critical to the life of the
hub bearing.
(1) Position hub/bearing assembly on rear spindle.
(2) Installa new hub nut(Fig. 101) and tighten
to a torque of 217 N´m (160 ft. lbs.).
(3) Install the dust cap, on the hub/bearing using a
soft faced hammer.
(4) On drum brake equipped vehicles, install the
brake drum on the hub/bearing. On vehiclesequipped with rear disc brakes, install the rotor on
the hub/bearing.
(5) On disc brake equipped vehicles install the disc
brake caliper on the adapter. Install the 2 guide pin
bolts (Fig. 102) mounting the disc brake caliper to
the adapter. Tighten the guide pin bolts to a torque
of 22 N´m (192 in. lbs.). Refer To Rear Disc Brake
Service in this group of the service manual for the
required caliper installation procedure.
(6) Install rear wheel and tire assembly on vehicle.
Tighten all wheel stud nuts in criss cross pattern to
one-half specified torque. Then repeat pattern, fully
tightening stud nuts to 135 N´m (100 ft. lbs.).
(7) Lower vehicle.
Fig. 98 Brake Drum Removal
Fig. 99 Rear Rotor Removal
Fig. 100 Rear Hub/Bearing Dust Cap
Fig. 101 Hub/Bearing Assembly Retaining Nut
5 - 40 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

MASTER CYLINDER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, be sure engine is
not running, and pump the brake pedal until a firm
pedal is achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector, from
brake fluid level sensor, in master cylinder brake
fluid reservoir (Fig. 103).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 104) and (Fig.
105). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner product such as Mopar Brake
Parts Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 106) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 107) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 107) located in the front of the power
brake vacuum booster. Vacuum seal is removed by
Fig. 102 Caliper Guide Pin Bolts
Fig. 103 Master Cylinder Fluid Level Sensor
Fig. 104 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 105 Primary And Secondary Brake Tubes With
ABS Brakes
PLBRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)

carefullyinserting a small screw driver between the
push rod of the power brake vacuum booster and vac-
uum seal (Fig. 107) and pry seal out of power brake
vacuum booster.Do not attempt to pry seal out of
master cylinder by inserting a tool between
seal and power brake vacuum booster.
BLEEDING MASTER CYLINDER
(1) Clamp the master cylinder in a vise. Attach
Bleeding Tubes, Special Tool 6802 to the master cyl-
inder (Fig. 108) and (Fig. 109). Position tubes so out-
lets of Bleeding Tubes will be below surface of brake
fluid when reservoir is filled to proper level.
(2) Fill brake fluid reservoir with brake fluid con-
forming to DOT 3 specifications such as Mopar or an
Equivalent.
(3) Using a wooden dowel per (Fig. 110), depress
push rod slowly and then allow pistons to return to
released position. Repeat several times until all air
bubbles are expelled.
Fig. 106 Master Cylinder Mounting To Vacuum
Booster
Fig. 107 Removing Seal From Vacuum Booster
Fig. 108 Bleeding Tubes Attached to ABS Master
Cylinder
Fig. 109 Bleeding Tubes Attached To Non-ABS
Master Cylinder
Fig. 110 Bleeding Master Cylinder
5 - 42 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Remove bleeding tubes from master cylinder
outlet ports, plug outlet ports and install fill cap on
reservoir.
(5) Remove master cylinder from vise.
NOTE: Note: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der. But the master cylinder must have been bled
and filled upon installation.
INSTALL
CAUTION: When replacing the master cylinder on
a vehicle equipped with ABS, a NEW vacuum seal
MUST be installed in the power brake vacuum
booster. Use only the procedure detailed below for
installing vacuum seal into power brake vacuum
booster. Be sure old vacuum seal is removed from
power brake vacuum booster before attempting to
install new seal.
CAUTION: When lubricating master cylinder push
rod, use only Mopar Silicone Dielectric Compound.
Using any other type of grease or lubricant on the
push rod, will not provide adequate long term lubri-
cation of the push rod.
(1) Lubricate master cylinder push rod as indi-
cated in (Fig. 111) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(2) Install vacuum seal on master cylinder push
rod as shown in (Fig. 112) with notches on vacuum
seal pointing toward master cylinder housing. Then
slide vacuum seal onto master push rod until seal is
seated against master cylinder housing (Fig. 113)
before installing master cylinder on power brake vac-
uum booster.CAUTION: If vehicle is equipped with ABS, be sure
old vacuum seal is removed from power brake vac-
uum booster before attempting to install master cyl-
inder and NEW vacuum seal. If vacuum seal is not
removed, refer to Master Cylinder Removal in this
section of the service manual for required vacuum
seal removal procedure.
(3) Position master cylinder on studs of power
brake unit, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(4) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 106) and torque to 28 N´m
(250 in. lbs.) torque.
(5) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 104) and (Fig. 105).
Torque all tube nuts to 17 N´m (145 in. lbs.) torque.
Fig. 111 Lubricating Master Cylinder Push Rod
Fig. 112 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 113 Vacuum Seal Positioned For Installing
Master Cinder
PLBRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

VACUUM BOOSTER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, with engine not
running, pump the brake pedal until a firm pedal is
achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector from
brake fluid level sensor located in master cylinder
brake fluid reservoir (Fig. 114).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 115) and (Fig.
116). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner such as Mopar Brake Parts
Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 117) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 118) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 118) located in the front of the power
Fig. 114 Master Cylinder Fluid Level Sensor
Fig. 115 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 116 Primary And Secondary Brake Tubes With
ABS Brakes
Fig. 117 Master Cylinder Mounting To Vacuum
Booster
5 - 44 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

brake vacuum booster. Vacuum seal is removed by
carefullyinserting a small screw driver between the
push rod of the power brake vacuum booster and vac-
uum seal (Fig. 118) and prying seal out of power
brake vacuum booster.Do not attempt to pry seal
out of master cylinder by inserting a tool
between seal and power brake vacuum booster.
(8) Disconnect vacuum hoses from check valve on
power brake vacuum booster (Fig. 119).Do not
remove check valve from power brake vacuum
booster.
NOTE: If vehicle is equipped with antilock brakes,
the hydraulic control unit (HCU) needs to be
removed from the vehicle to allow removal of the
power brake vacuum booster. Refer to Antilock
Brake System Hydraulic Control Unit in the
Removal And Installation Section of the Antilock
Brake System Section of this service manual for the
required procedure.(9) Locate the power brake vacuum booster input
rod to brake pedal attachment under instrument
panel. Position a small screwdriver (Fig. 120) under
the center tang of the retaining clip.
CAUTION: Discard retaining clip when removed, it
is not to be reused. Replace only with a new retain-
ing clip when assembled.
(10) Rotate screwdriver (Fig. 120) enough to allow
retaining clip tang to pass over the end of the brake
pedal pin.
(11) Remove the 4 nuts attaching the power brake
vacuum booster to the dash panel (Fig. 121). The
nuts are accessible from under the instrument panel
in the area of the steering column and brake pedal
bracket.
(12) Slide power brake vacuum booster forward
until mounting studs clear dash panel, then tilt the
booster up and to the center of the vehicle to remove.
Fig. 118 Vacuum Seal Removal From Power Brake
Booster
Fig. 119 Power Brake Vacuum Booster Check Valve
Fig. 120 Input Rod Retaining Pin
Fig. 121 Power Brake Booster Mounting
PLBRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Position power brake booster onto dash panel.
(2) Install and torque the 4 power brake vacuum
booster mounting nuts (Fig. 121) to 29 N´m (250 in.
lbs.) torque.
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake vacuum booster input rod.
(4) Connect power brake vacuum booster input rod
to brake pedal pin and install a NEW retaining clip.
Use only a new retainer clip DO NOT USE the
old clip.
(5) Connect all previously removed vacuum hoses
onto power brake vacuum booster check valve (Fig.
119).
(6) If vehicle is equipped with ABS, install HCU.
Refer to Antilock Brake System Hydraulic Control
Unit in the Removal And Installation Section of the
Antilock Brake System Section of this service manual
for the required procedure.
CAUTION: When replacing the power brake vac-
uum booster on a vehicle equipped with ABS, a
NEW vacuum seal MUST be installed in the power
brake vacuum booster. Use only the procedure
detailed below for installing vacuum seal into power
brake vacuum booster. If old vacuum seal came out
with master cylinder when it was removed from
power brake vacuum booster, be sure it is removed
from master cylinder before attempting to install
master cylinder into power brake vacuum booster.
CAUTION: When lubricating master cylinder push
rod, use only Mopar Silicone Dielectric Compound.
Using any other type of grease or lubricant on the
push rod, will not provide adequate long term lubri-
cation of the push rod.
(7) Lubricate master cylinder push rod as indi-
cated in (Fig. 122) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(8) Install vacuum seal on master cylinder push
rod as shown with notches on vacuum seal pointing
toward master cylinder housing (Fig. 123). Then slide
vacuum seal onto master push rod until seal is
seated against master cylinder housing (Fig. 124)
before installing master cylinder on power brake vac-
uum booster.
CAUTION: If vehicle is equipped with ABS, be sure
the old vacuum seal is removed from power brake
vacuum booster before attempting to install master
cylinder and NEW vacuum seal. If vacuum seal is
not removed, refer to Master Cylinder Removal in
this section of the service manual for required vac-
uum seal removal procedure.
Fig. 122 Lubricating Master Cylinder Push Rod
Fig. 123 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 124 Vacuum Seal Positioned For Installing
Master Cylinder
5 - 46 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(9) Position master cylinder on studs of power
brake unit, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(10) Install the 2 master cylinder mounting nuts
(Fig. 117) and torque to 28 N´m (250 in. lbs.) torque.
(11) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 115) and (Fig. 116).
Torque all tube nuts to 17 N´m (145 in. lbs.) torque.
(12) Reconnect wiring connector to fluid level sen-
sor.
(13) Adjust stop lamp switch as necessary.
(14) Bleed brake system.
CHASSIS TUBES AND HOSES
Always use Mopar replacement brake hose assem-
blies to ensure quality, correct length and superior
fatigue life. Care should be taken to make sure that
the tube and hose mating surfaces are clean and free
from nicks and burrs.Hose assemblies for each
brake are unique and not interchangeable.
Use new copper seal washers on all connections
using Banjo Bolts and tighten all fittings to their
specified torques.
The flexible front hydraulic brake hose should
always be installed on the vehicle by first attaching
the Banjo connector to the caliper assembly. Then
bolt the intermediate hose bracket to the strut
assembly allowing the bracket to position the hose to
prevent twisting. Attach the hose to brake tubing,
before attaching to front frame rail. Then tighten all
brake line fittings to specified torque.
On vehicles equipped with rear drum brakes,
install rear brake hoses first to wheel cylinders and
rear struts and then attach hose bracket to body. On
vehicles equipped with rear disc brakes, attach brake
hoses to calipers and struts first and then attach
brake hose bracket to body. Following this procedure
will reduce potential for twisting brake during instal-
lation procedure.
Only double wall 4.75mm (3/16 in.) steel brake line
tubing, with Al- Rich/ZN-AL alloy coating should be
used for replacement. Care must be taken when
replacing brake tubing, to be sure the proper bending
and flaring tools and procedures are used to avoid
kinking. Do not route the tubes against sharp edges,
moving components or into hot areas. All tubes
should be properly attached with recommended
retaining clips.
PROPORTIONING VALVE (BASE BRAKES)
CAUTION: Proportioning valves (Fig. 125) should
never be disassembled.
There are two proportioning valve assemblies used
in each vehicle. Due to different thread sizes, each
proportioning valve has a different part number. Dur-ing any service procedures identify the proportioning
valve assemblies by supplier part number and or the
color identification band (Fig. 125).
If premature rear wheel skid occurs on hard brake
application, it could be an indication that a malfunc-
tion has occurred with one of the proportioning
valves.
One proportioning valve controls the right rear
brake, and the other proportioning valve controls the
left rear brake (Fig. 126). Therefore, a road test to
determine which rear brake slides first is essential.
If a malfunctioning proportioning valve is sus-
pected on a vehicle. Refer to Brake Hydraulic System
Control Valves in the Diagnosis And Testing Section
in this group of the service manual for the required
test procedure.
REMOVE
Use the proportioning valve test procedure stated
above to determine which proportioning valve
requires replacement, then replace it using procedure
below.
(1) Disconnect brake tube from proportioning valve
requiring removal from the master cylinder (Fig.
126).
(2) Remove proportioning valve (Fig. 126) from the
master cylinder requiring replacement.
INSTALL
(1) Wet O-ring seal on new proportioning valve
using clean fresh brake fluid.
(2) Install proportioning valve in master cylinder
and hand tighten until proportioning valve and
O-ring seal is fully seated in master cylinder. Torque
proportioning valve to 40 N´m (30 ft. lbs.).
(3) Install brake tube on proportioning valve.
Tighten tube nut to 17 N´m (145 in lbs.) torque.
(4) Bleed the affected brake line. See Bleeding
Base Brake Hydraulic System in the Service Proce-
dures Section in this group of the service manual for
the proper bleeding procedure.
Fig. 125 Proportioning Valve
PLBRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)

PARK BRAKE LEVER ASSEMBLY
WARNING: THE AUTO ADJUSTING FEATURE OF
THIS PARKING BRAKE LEVER ASSEMBLY CON-
TAINS A CLOCK SPRING LOADED TO APPROXI-
MATELY 20 POUNDS. DO NOT RELEASE THE AUTO
ADJUSTER LOCKOUT DEVICE BEFORE INSTALL-
ING CABLES INTO THE EQUALIZER. KEEP HANDS
OUT OF AUTO ADJUSTER SECTOR AND PAWL
AREA. FAILURE TO OBSERVE CAUTION IN HAN-
DLING THIS MECHANISM COULD LEAD TO SERI-
OUS INJURY.
REMOVE
(1) Remove the screws attaching the rear of the
center console assembly to console bracket (Fig. 127)
or (Fig. 128).(2) Remove the 2 screws located in cup holders
(Fig. 129), attaching front of center console assembly
to console bracket.
(3) Raise park brake hand lever as high as it will
go to get the required clearance to remove the center
console.
(4) Remove center console assembly.
WARNING: WHEN REPAIRS TO THE PARK BRAKE
HAND LEVER ASSEMBLY OR CABLES IS
REQUIRED, THE AUTO ADJUSTER MUST BE
RELOADED AND LOCKED OUT.
(5) Lower park brake lever handle.
(6) Grasp park brake lever output cable by hand
and pull rearward (Fig. 130). Continue pulling on
cable until a 3/16 in. drill bit can be inserted into
handle and sector gear of park brake mechanism
(Fig. 130). This will lock the park brake mechanism
and take tension off park brake cables.
Fig. 126 Non-ABS Proportioning Valve Locations On
Master Cylinder
Fig. 127 Center Console Rear Attaching Screws W/O
Arm Rest
Fig. 128 Center Console Rear Attaching Screws
With Arm Rest
Fig. 129 Attaching Screws At Front Of Center
Console
5 - 48 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(7) Remove both rear park brake cables from the
park brake cable equalizer (Fig. 131).
(8) Remove wiring harness electrical connector for
brake warning light ground from the park brake
lever (Fig. 132).
(9) Remove the 2 nuts (Fig. 133) attaching the
park brake lever to the console bracket. Remove park
brake lever mechanism from vehicle.
INSTALL
(1) Place park brake lever on console bracket.
Install and securely tighten the 2 attaching nuts
(Fig. 133).
(2) Install both rear park brake cables into equal-
izer on park brake lever output cable (Fig. 131).
(3) Ensure that park brake cable is correctly
installed and aligned with cable track on park brake
lever.
(4) Firmly grasp park brake lever locking pin (Fig.
134) and quickly remove it from the park brake levermechanism. This will allow the park brake lever
mechanism to correctly adjust the park brake cables.
(5) Connect electrical connector for brake warning
lamp onto terminal on park brake lever assembly
(Fig. 132).
(6) Cycle park brake lever once to position park
brake cables. Then return the park brake lever its
released position. Check the rear wheels of the vehi-
cle. They should rotate freely without dragging.
(7) Raise park brake lever to its fully engaged
position. This is necessary to allow installation of the
center console.
(8) Install center console assembly.
(9) Install the 4 center console assembly attaching
screws (Fig. 127), (Fig. 128) and (Fig. 129).
PARK BRAKE LEVER OUTPUT CABLE
On this vehicle, the park brake lever output cable
(Fig. 135), is not replaceable as a separate component
Fig. 130 Locking Pin Installed In Park Brake
Mechanism
Fig. 131 Park Brake Cables At Equalizer
Fig. 132 Brake Warning Lamp Connection To Park
Brake Lever
Fig. 133 Park Brake Lever Attachment To Console
Bracket
PLBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)