DODGE NEON 1999 Service Repair Manual

sleeve (Fig. 176). Be sure other end of bushing did
not come out of seal grove in sleeve.
(8) When the sleeve is seated properly into the
bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve
groove.CALIPER DISASSEMBLY
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE EVER BE USED TO REMOVE A PISTON
FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
(1) Remove caliper from brake rotor (See Brake
Shoe Removal). Hang assembly on a wire hook away
Fig. 173 Installing Caliper Guide Pin Bushing
Fig. 174 Bushing Correctly Installed In Caliper
Fig. 175 Installing Sleeve In Bushing
Fig. 176 Correctly Installed Caliper Sleeve And
Bushing
5 - 60 BRAKESPL
DISASSEMBLY AND ASSEMBLY (Continued)

from rotor, so hydraulic fluid cannot get on rotor.
Place a small piece of wood between the piston and
caliper fingers.
(2)Carefullydepress brake pedal to hydraulically
push piston out of bore. Then apply and hold down
the brake pedal to any position beyond the first inch
of pedal travel. This will prevent loss of brake fluid
from the master cylinder.
(3) If both front caliper pistons are to be removed,
disconnect brake tube at flexible brake hose at frame
rail. Plug brake tube and remove piston from oppo-
site caliper using the same process as above for the
first piston removal.
(4) Disconnect the brake fluid flex hose from the
caliper assembly.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
(5) To disassemble caliper, mount in a vise
equipped with protective jaws.
(6) Remove guide pin sleeves and guide pin bush-
ings. See Removing Guide Pin Bushings in the cali-
per disassembly section of this manual.
(7) Remove the piston dust boot from the caliper
and discard (Fig. 177).
(8) Using a soft tool, such as a plastic trim stick,
work piston seal out of its groove in caliper piston
bore (Fig. 178). Discard old seal.Do not use a
screw driver or other metal tool for this opera-
tion, because of the possibility of scratching
piston bore or burring edges of seal groove.(9) Clean all parts using alcohol or a suitable sol-
vent and wipe dryusing only a lint free cloth.No
lint residue can remain in caliper bore. Clean out all
drilled passages and bores.Whenever a caliper
has been disassembled, a new boot and seal
must be installed at assembly.
(10) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or
scoring should be honed. Use Caliper Hone, Special
Tool C-4095, or equivalent providing the diameter of
the bore is not increased more than 0.0254 mm
(0.001 inch) (Fig. 179).
(11) If the bore does not clean up within this spec-
ification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
NOTE: When using Caliper Honing Tool, Special
Tool C-4095, coat the stones and bore with brake
fluid. After honing the bore, carefully clean the seal
and boot grooves with a stiff non-metallic rotary
brush.
NOTE: Use extreme care in cleaning the caliper
after honing. Remove all dirt and grit by flushing
the caliper with brake fluid; wipe dry with a clean,
lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not
use anything but solvents to clean piston surface. If
surface of piston cannot be cleaned using only sol-
vents, piston must be replaced.
Fig. 177 Removing Caliper/Piston Dust Boot
Fig. 178 Removing Piston Seal From Caliper
PLBRAKES 5 - 61
DISASSEMBLY AND ASSEMBLY (Continued)

(12) Inspect caliper piston for pitting, scratches, or
any physical damage. Replace piston if there is evi-
dence of scratches, pitting or physical damage.
CALIPER ASSEMBLY
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
(1) Clamp caliper in a vise (with protective caps
installed on jaws of vise).
(2) Dip new piston seal in clean brake fluid and
install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove (Fig. 180), using only your
fingers until properly seated.NEVER USE AN OLD
PISTON SEAL.Be sure that fingers are clean and
seal is not twisted or rolled (Fig. 180).
(3) Coat new piston boot with clean brake fluid
leaving a generous amount inside boot.
(4) Position dust boot over piston after coating
with brake fluid.
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
(5) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 181).
(6) Position dust boot into the counterbore of the
caliper assembly piston bore.
(7) Using a hammer and Installer Piston Caliper
Boot, Special Tool C-4689 and Handle, Special ToolC-4171, drive boot into counterbore of the caliper
(Fig. 182).
(8) Install guide pin sleeves and bushings. See
Install Guide Pin Bushings section in the caliper dis-
assembly section of this manual.
(9) Install brake pads. See Installing Brake Pads
in the Brake Pad Service Procedures section of this
manual.
(10) Before installing caliper assembly on vehicle,
inspect brake rotor. If any conditions as described in
Checking Brake Rotor for Runout and Thickness are
present the rotor, must be replaced or refaced. If the
rotor does not require any servicing, install caliper
assembly.
(11) Install brake hose onto caliper using banjo
bolt. Torque the brake hose to caliper assembly banjo
bolt to 33 N´m (24 ft. lbs.).New seal washers
Fig. 179 Honing Brake Caliper Piston Bore
Fig. 180 Installing New Piston Seal In Caliper
Fig. 181 Installing Piston Into Caliper Bore
5 - 62 BRAKESPL
DISASSEMBLY AND ASSEMBLY (Continued)

MUST always be used when installing brake
hose to caliper.
(12) Bleed the brake system (see Bleeding Brake
System).
WHEEL CYLINDER (REAR DRUM BRAKE)
DISASSEMBLE
To disassemble the wheel cylinders, proceed as fol-
lows:
(1) Pry boots away from cylinders and remove (Fig.
183).
(2) PressINon one piston to force out opposite
piston, cup and spring (Fig. 183). Then using a soft
tool such as a dowel rod, press out the cup and piston
that remain in the wheel cylinder.
(3) Wash wheel cylinder, pistons, and spring (Fig.
183) in clean brake fluid or alcohol;(DO NOT USE
ANY PETROLEUM BASE SOLVENTS)clean thor-
oughly and blow dry with compressed air. Inspect cyl-
inder bore and piston for scoring and pitting. (Do not
use a rag as lint from the rag will stick to bore sur-
faces.)
(4) Wheel cylinder bores and pistons that are
badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of cor-
rosion, can usually be cleaned with crocus cloth,
using a circular motion. Black stains on the cylinder
walls are caused by piston cups and will not impair
operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the
wheel cylinders, dip them in clean brake fluid. If theboots are deteriorated, cracked or do not fit tightly on
the pistons or the cylinder casting, install new boots.
(1) Coat cylinder bore with clean brake fluid.
(2) Lightly coat the sealing lip and outer surfaces
of the wheel cylinder cups with Mopar Protect-A-Cup
Lubricant.
(3) Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with
open end of cups facing each other (Fig. 183).
(4) Install piston in each end of cylinder having
the flat face of each piston contacting the flat face of
each cup, already installed (Fig. 183).
(5) Coat the interior surfaces of the push on boots
(Fig. 183) with the Mopar Protect-A-Cup Lubricant
(6) Install a boot over each end of cylinder (Fig.
183).Be careful not to damage boot during
installation.
CLEANING AND INSPECTION
FRONT DISC BRAKES
BRAKE PAD LINING WEAR
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the wheel and tire assemblies, and the cali-
pers.
Remove the front disc brake shoes. Refer to Front
Disc Brake Shoe Removal in the Removal And Instal-
lation section in this group of the service manual for
the required procedure.
The combined brake shoe and lining material
thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total
thickness of approximately 7.95 mm (5/16 inch) they
should be replaced.
Replacebothbrake shoe assemblies (inboard and
outboard). It is necessary thatbothfront wheel sets
be replaced whenever brake shoe assemblies on
either side are replaced.
If the brake shoe assemblies do not require
replacement, reinstall, the assemblies making sure
each brake shoe is returned to the original position.
Refer to Front Disc Brake Shoe Installation in the
Removal And Installation section in this group of the
service manual for the required procedure.
CALIPER INSPECTION
Check for brake fluid leaks in and around boot
area and inboard lining, and for any ruptures, brit-
tleness or damage to the piston dust boot. If the boot
Fig. 182 Installing Dust Boot In Caliper Counterbore
PLBRAKES 5 - 63
DISASSEMBLY AND ASSEMBLY (Continued)

is damaged, or a fluid leak is visible, disassemble cal-
iper assembly and install a new seal and boot, and
piston if scored. Refer to Front Disc Brake Caliper in
the Disassembly And Assembly Section in this group
of the service manual.
Check the guide pin dust boots to determine if they
are in good condition. Replace if they are damaged,
dry, or found to be brittle. Refer to Front Disc Brake
Caliper in the Disassembly And Assembly Section in
this group of the service manual.
REAR DISC BRAKES
BRAKE PAD LINING WEAR
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the wheel and tire assemblies, and the cali-
pers.
Remove the rear disc brake shoes. Refer to Rear
Disc Brake Shoe Removal in the Removal And Instal-
lation section in this group of the service manual for
the required procedure.
The combined brake shoe and lining material
thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total
thickness of approximately 7.0 mm (9/32 inch) they
should be replaced.
Replacebothbrake shoe assemblies (inboard and
outboard). It is necessary thatbothrear wheel sets
be replaced whenever brake shoe assemblies on
either side are replaced.
If the brake shoe assemblies do not require
replacement, reinstall, the assemblies making sureeach brake shoe is returned to the original position.
Refer to Rear Disc Brake Shoe Installation in the
Removal And Installation section in this group of the
service manual for the required procedure.
CALIPER INSPECTION
Check for brake fluid leaks in and around boot
area and inboard lining, and for any ruptures, brit-
tleness or damage to the piston dust boot. If the boot
is damaged, or a fluid leak is visible, disassemble cal-
iper assembly and install a new seal and boot, and
piston if scored. Refer to Rear Disc Brake Caliper in
the Disassembly And Assembly Section in this group
of the service manual.
Check the guide pin dust boots to determine if they
are in good condition. Replace if they are damaged,
dry, or found to be brittle. Refer to Rear Disc Brake
Caliper in the Disassembly And Assembly Section in
this group of the service manual.
REAR DRUM BRAKES
Rear brake shoe lining should show contact across
entire width of the lining and also from the heel to
the toe of the lining, otherwise replace.
Brake shoes with lack of contact at the toe or heel
of the brake shoe linng may be improperly ground.
Clean and inspect the brake support plate and
adjusting screws. Apply a thin coat of Mopar Multi-
Purpose Lubricant or equivalent to the threads of the
self adjuster (Fig. 184). Replace adjusting screw if
corroded.
Fig. 183 Rear Wheel Cylinder (Exploded View)
5 - 64 BRAKESPL
CLEANING AND INSPECTION (Continued)

If old brake shoe return or hold down springs have
overheated or are damaged, replace. Overheating
indications are paint discoloration or distorted end
coils.
REAR DRUM BRAKE WHEEL CYLINDER
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
CHASSIS TUBES AND HOSES
Flexible rubber hose is used at both front and rear
brakes. Inspection of brake hoses should be per-
formed whenever the brake system is serviced and
every 7,500 miles or 12 months, whichever comes
first (every engine oil change). Inspect hydraulic
brake hoses for severe surface cracking, scuffing,
worn spots or physical damage. If the fabric casing of
the rubber hose becomes exposed due to cracks or
abrasions in the rubber hose cover, the hose should
be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure.
Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.
The steel brake tubing should be inspected periodi-
cally for evidence of corrosion, physical damage or con-
tact with moving or hot components of the vehicle.
REAR WHEEL HUB AND BEARING ASSEMBLY
The rear hub and bearing assembly is designed for
the life of the vehicle and should require no mainte-
nance. The following procedure may be used for eval-
uation of bearing condition.
With wheel and brake drum removed, rotate
flanged outer ring of hub. Excessive roughness, lat-
eral play or resistance to rotation may indicate dirt
intrusion or bearing failure. If the rear wheel bear-
ings exhibit these conditions during inspection, the
hub and bearing assembly should be replaced.Damaged bearing seals and resulting excessive
grease loss may also require bearing replacement.
Moderate grease loss from bearing is considered nor-
mal and should not require replacement of the hub
and bearing assembly.
ADJUSTMENTS
STOP LAMP SWITCH
(1) Remove stop lamp switch from its bracket by
rotating it approximately 30É in a counter-clockwise
direction.
(2) Disconnect wiring harness connector from stop
lamp switch.
(3) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(4) Install the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp
switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting
bracket. When switch is fully installed in the square
hole of the bracket, rotate switch clockwise approxi-
mately 30É to lock the switch into the bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If too much force is used, damage to the vacuum
booster, stop lamp switch or striker (Fig. 185) can
result.
(5) Connect the wiring harness connector to the
stop lamp switch.
(6) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger
(Fig. 185) to ratchet backward to the correct position.
REAR DRUM BRAKE SHOE ADJUSTMENT
NOTE: Normally, self adjusting drum brakes will
not require manual brake shoe adjustment.
Although in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
(1) Raise the vehicle so all wheels are free to turn.
See Hoisting Recommendations in the Lubrication
And Maintenance Section at the front of this service
manual.
(2) Remove rear brake adjusting hole rubber plug
(Fig. 186) from the rear brake shoe support plate.
Fig. 184 Adjuster Screw And Lever (Typical)
PLBRAKES 5 - 65
CLEANING AND INSPECTION (Continued)

(3)Be sure parking brake lever is fully
released.
(4) Insert Brake Adjuster, Special Tool C-3784,
(Fig. 187) or equivalent, through the adjusting hole
in support plate and against star wheel of adjusting
screw. Move handle of tool downward until a slight
drag is felt when the road wheel is rotated.
(5) Insert a thin screwdriver or piece of welding
rod into brake adjusting hole (Fig. 187). Push adjust-
ing lever out of engagement with star wheel.Care
should be taken so as not to bend adjusting
lever or distort lever spring.While holding
adjusting lever out of engagement with star wheel,
back off star wheel to ensure a free wheel with no
brake shoe drag.
(6) Repeat above adjustment at the other rear
wheel. Install adjusting hole rubber plugs (Fig. 186)
in rear brake supports.
(7) Apply and release the park brake lever one
timeafterwheel brake adjustment.
PARK BRAKE ADJUSTMENT
VEHICLE EQUIPPED REAR DRUM BRAKES
Due to the auto adjust feature of the park brake
lever, no manual adjustment of the operating cables
for the park brake system is required. On vehicles
equipped with rear drum brakes, proper operation of
the park brake relies on proper adjustment of the
rear drum brake shoes. See Rear Brake Adjustment
in the Service Adjustments Section in this group of
the service manual.
VEHICLE EQUIPPED REAR DISC BRAKES
Due to the auto adjust feature of the park brake
lever, no manual adjustment of the operating cables
for the park brake system is required. On vehicles
equipped with rear disc brakes, proper operation of
the park brake relies on the proper adjustment of the
drum-in-hat park brake shoes. Refer to the following
procedure to correctly adjust the drum-in-hat park
brake shoes.
NOTE: The park brake shoes used in the drum-in-
hat park brake system do not automatically adjust
to compensate for brake shoe lining wear. There-
fore, it is necessary to manually adjust the park
brake shoes. Manual adjustment of the park brake
shoes is required whenever any of the following
occurs. Excessive travel of the of the park brake
lever, new park brake shoes are installed, or any
service is performed that effects the location of the
park brake shoes like: replacing hold down clips,
return springs, adjuster mechanism etc.
(1) Fully release the park brake hand lever.
(2) Raise vehicle. See Hoisting Recommendations
in the Lubrication And Maintenance Section of this
service manual.
Fig. 185 Stop Light Switch Location In Vehicle
Fig. 186 Rear Brake Adjusting Hole Plug
Fig. 187 Brake Drum Adjustment With Tool C-3784
5 - 66 BRAKESPL
ADJUSTMENTS (Continued)

(3) Remove the rubber plug from the adjusting
hole in the brake shoe backing plate on both sides of
the vehicle.
(4)Driver (left) side park brake shoe adjust-
ment procedure.Insert a medium size screwdriver
through adjustment hole in backing plate. Position
the srewdriver against the starwheel on the park
brake shoe adjuster mechanism. Using the screw-
driver rotate the starwheeldownwarduntil a slight
drag is felt when turning the rear tire and wheel.
Then, using the screwdriver rotate the starwheel
upwardjust until the rear tire and wheel can be
rotated with no park brake shoe drag. From the
point where there is no more park brake drag rotate
the starwheelupwarda maximum of two additional
clicks. The park brake shoe to drum clearance is
know properly adjusted.
(5)Passenger (right) side park brake shoe
adjustment procedure.Insert a medium size
screwdriver through adjustment hole in backing
plate. Position the srewdriver against the starwheel
on the park brake shoe adjuster mechanism. Using
the screwdriver rotate the starwheelupwarduntil a
slight drag is felt when turning the rear tire and
wheel. Then, using the screwdriver rotate the star-
wheeldownwardjust until the rear tire and wheel
can be rotated with no park brake shoe drag. From
the point where there is no more park brake drag
rotate the starwheeldownwarda maximum of two
additional clicks. The park brake shoe to drum clear-
ance is know properly adjusted.
(6) Install the rubber plug in the adjusting hole on
the brake shoe backing plate on both sides of the
vehicle.
(7) Lower vehicle far enough to allow access the
park brake lever. The rear tires must not be on the
ground.
(8) Fully apply and release the park brakes two
times after adjusting the park brake shoes. Then
rotate both rear wheels to ensure that the park
brake shoes do not drag on the brake drum following
the application and release of the park brakes.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. Anopen container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
MASTER CYLINDER ASSEMBLY:
Type ...........................Dual Tandem
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE / STROKE
AND SPLIT:
NonABS ....21mmx32.6 mm (.875 in. x 1.28 in.)
ABS........21mmx32.7 mm (.874 in. x 1.29 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
ABS ..........Primary 3/8±24 Secondary 7/16±24
Non ABS . . .Primary Inboard And Outboard 7/16±24
Non ABS . . .Secondary Inboard And Outboard 3/8±23
Outlet Fitting Type.......SAE 45 É Inverted Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type.SAE 45 É Inverted Flare
BOOSTER:
Make/Type.........Bendix Vacuum W/&W/O ABS
Mounting Studs.....................M8x1.25
Type ..........................230 mm Single
Boost At 20 inches Of Manifold Vacuum. . . .4690 All
PROPORTIONING VALVE:
Material...........................Aluminum
Function........Hydraulic Pressure Proportioning
BRAKE PEDAL
Pedal Ratio.............................3.28
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To
HCU At HCU Ports........21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
PLBRAKES 5 - 67
ADJUSTMENTS (Continued)

DESCRIPTION TORQUE
MASTER CYLINDER:
To Vacuum Booster Mounting Nut.28 N´m (250 in. lbs.)
BRAKE BOOSTER:
To Dash Panel Mounting Nuts . .28 N´m (250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate Mounting Bolts.13 N´m (115 in. lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
REAR DISC BRAKE ADAPTER:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts.............22N´m(192 in. lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
To Mounting Bracket Bolts.....28N´m(250 in. lbs.)
Bracket To Frame Rail Mounting Bolt (Top) . .18 N´m
(160 in. lbs.)
Bracket To Frame Rail Mounting Bolts (Side).22 N´m
(200 in. lbs.)
PARKING BRAKE:
Lever Mounting Nuts.........28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Knuckle Retaining Nut.....217 N´m (160 ft. lbs.)
WHEEL:
Stud Lug Nut........109±150 N´m (80±110 ft. lbs.)
SPECIAL TOOLS
BASE BRAKE SYSTEM
Adapters, Brake Pressure Test 6805
Gauge Set C-4007-A
Handle, Universal C-4171
Installer, Dust Boot C-4689
Dial Indicator C-3339
Tubes, Master Cylinder Bleeding 6802
5 - 68 BRAKESPL
SPECIFICATIONS (Continued)

ANTILOCK BRAKE SYSTEM±TEVES MARK 20
INDEX
page page
DESCRIPTION AND OPERATION
ABS BRAKE SYSTEM COMPONENTS........ 71
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE....................... 69
ABS COMPONENT ABBREVIATION LIST...... 69
ABS FLUID ACCUMULATORS.............. 72
ABS FUSES............................ 73
ABS MASTER CYLINDER AND POWER BRAKE
BOOSTER............................ 71
ABS RELAYS........................... 73
ABS WARNING LAMP (YELLOW)............ 75
ANTILOCK BRAKES OPERATION
DESCRIPTION........................ 69
CONTROLLER ANTILOCK BRAKES (CAB)..... 74
HCU PUMP/MOTOR..................... 72
HYDRAULIC CIRCUITS AND VALVE
OPERATION.......................... 75
INLET VALVES AND SOLENOIDS............ 72
INTEGRATED CONTROL UNIT (ICU)......... 71
OUTLET VALVES AND SOLENOIDS.......... 72
PROPORTIONING VALVE................. 73
WHEEL SPEED SENSORS................. 73
DIAGNOSIS AND TESTING
ABS DIAGNOSTIC TROUBLE CODES........ 78
ABS DIAGNOSTICS MANUAL.............. 76
ABS GENERAL DIAGNOSTICS INFORMATION . 75
ABS SERVICE PRECAUTIONS.............. 76
ABS SYSTEM SELF DIAGNOSTICS.......... 77ABS WIRING DIAGRAM INFORMATION....... 76
BRAKE FLUID CONTAMINATION............ 80
DRB DIAGNOSTIC CONNECTOR............ 77
DRB DIAGNOSTIC SCAN TOOL USAGE...... 77
INTERMITTENT DIAGNOSTIC TROUBLE
CODES.............................. 78
PROPORTIONING VALVE................. 79
TEST DRIVING ABS COMPLAINT VEHICLE.... 80
TONEWHEEL INSPECTION................ 79
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM............................. 81
BRAKE FLUID LEVEL INSPECTION.......... 80
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS..... 81
ABS HYDRAULIC CONTROL UNIT........... 82
CONTROLLER ANTILOCK BRAKES (CAB)..... 86
FRONT WHEEL SPEED SENSOR........... 87
MASTER CYLINDER AND POWER BRAKE
BOOSTER............................ 86
PROPORTIONING VALVES................ 86
REAR WHEEL SPEED SENSOR............ 88
SPECIFICATIONS
BRAKE FASTENER TORQUE SPECIFICATIONS . 89
SPEED SENSOR TONE WHEEL RUNOUT..... 89
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE.......................... 89
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Antilock Brake System (ABS) is
to prevent wheel lock-up under braking conditions on
virtually any type of road surface. Antilock Braking
is desirable because a vehicle which is stopped with-
out locking the wheels will retain directional stability
and some steering capability. This allows the driver
to retain greater control of the vehicle during brak-
ing.
This section of the service manual covers the
description and on car service for the ITT Teves
Mark 20 ABS Brake System. If other service is
required on the non ABS related components of the
brake system, refer to the appropriate section in this
group of the service manual for the specific service
procedure required.
ABS COMPONENT ABBREVIATION LIST
In this section of the service manual, several
abbreviations are used for the components of the
Teves Mark 20 ABS Brake System. They are listed
below for your reference.
²CAB±Controller Antilock Brake
²ICU±Integrated Control Unit
²HCU±Hydraulic Control Unit
²ABS±Antilock Brake System
²PSI±Pounds Per Square Inch (pressure)
²WSS±Wheel Speed Sensor
²FWD±Front Wheel Drive
²DTC±Diagnostic Trouble Code
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE
This ABS System represents the current state-of-
the-art in vehicle braking systems and offers the
driver increased safety and control during braking.
PLBRAKES 5 - 69