torque DODGE NEON 1999 Service Service Manual

(4) Carefully lower caliper and brake shoe assem-
blies over braking disc (rotor) reversing the required
removal procedure (Fig. 71). Make sure that the cal-
iper guide pin bolts, bushings and sleeves are clear of
the adapter bosses.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(5) Install caliper assembly guide pin bolts into
adapter and tighten (Fig. 70). Then torque both guide
pin bolts to 22 N´m (192 in. lbs.).
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(8) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake pads.
REAR DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the braking rotor and caliper should
be done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, it should be
replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
NOTE: Before vehicle is moved after any brake
service work, pump the brake pedal several times
to insure the vehicle has a firm brake pedal.
NOTE: Starting with the 1998 model year, different
lining material is used on the rear disc brake shoes.
Vehicles equipped with optional 4 wheel disc
brakes use a new lining material on the rear disc
brake shoes than prior model year vehicles
equipped with this brake system. When new brake
shoes are installed, be sure brake shoes for the
correct model year and type of brake system the
vehicle is equipped with are used.REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the 2 caliper assembly to adapter
guide pin bolts (Fig. 74).
(4) Remove caliper assembly from adapter and
rotor by first rotating top of caliper assembly away
Fig. 74 Caliper Assembly Guide Pin Bolts
5 - 32 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

or fluid leak is visible, disassemble caliper and
install a new seal and boot, (and piston if scored).
Refer to Caliper Disassembly And Re-Assembly Pro-
cedures in Disc Brake Caliper Service in this section
of the service manual.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brit-
tle. Refer to Guide Pin Bushing Service in Disc
Brake Caliper Service in this section of the service
manual.
INSTALL
(1) Completely retract the caliper piston back into
the piston bore of the caliper assembly. This is
required for caliper installation when new brake pad
assemblies are installed on caliper.
(2) Lubricate both adapter abutments with a lib-
eral amount of MopartMultipurpose Lubricant, or
equivalent.
(3) Install rear rotor on the hub making sure it is
squarely seated on face of hub (Fig. 77).
(4) Remove protective paper from noise suppres-
sion gasket on both inner and outer brake pad
assemblies (if equipped).
(5) Install new inboard brake shoe assembly into
caliper piston by firmly pressing into piston bore
with thumbs (Fig. 79).Be sure inboard brake
shoe assembly is positioned squarely against
face of caliper piston.
(6) Slide new outboard brake pad assembly onto
the caliper assembly (Fig. 78). Be sure retaining clip
is squarely seated in the depressed areas on the cal-
iper.
CAUTION: Use care when installing caliper assem-
bly onto adapter, so the guide pin bushings andsleeves do not get damaged by the mounting
bosses on adapter.
(7) Carefully lower caliper and brake shoe assem-
blies over braking disc (rotor) reversing the required
removal procedure (Fig. 75). Make sure that caliper
guide pin bolts, bushings and sleeves are clear of the
adapter bosses.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(8) Install caliper assembly guide pin bolts into
adapter and tighten (Fig. 74). Then torque both guide
pin bolts to 22 N´m (192 in. lbs.).
(9) Install the wheel and tire assembly.
(10) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(11) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
REAR BRAKE DRUM
REMOVE
Further clearance can be obtained by backing off
the brake automatic adjuster screw. Remove rubber
plug from top of brake support plate. Rotate auto-
matic adjuster screw assembly with an upward
motion, using a medium size screwdriver.
See adjusting rear service brakes in the Service
Adjustments section in this group of the service man-
ual for the specific adjustment procedure.
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped).
(4) Remove rear brake drum from rear hub/bear-
ing assembly (Fig. 80).
(5) Inspect brake linings for wear, shoe alignment
and contamination.
INSTALL
(1) Install rear brake drum assembly on rear hub
and bearing assembly.
(2) Install the wheel and tire assembly.
Fig. 79 Removing Inboard Brake Shoe
5 - 34 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(3) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
REAR BRAKE SHOES
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove the brake drum to hub/bearing retain-
ing clips (if equipped) (Fig. 81).
(4) Remove the brake drum from the hub/bearing
(Fig. 82).
(5) Remove the adjustment lever to leading brake
shoe spring (Fig. 83).
(6) Remove the automatic adjustment lever (Fig.
84) from the brake shoe.(7) Remove hold down clips and pins attaching the
leading and trailing brake shoes to the brake support
plate (Fig. 85).
Fig. 80 Brake Drum And Hub/Bearing
Fig. 81 Rear Brake Drum
Fig. 82 Brake Drum Remove/Install
Fig. 83 Automatic Adjustment Lever Spring
Fig. 84 Automatic Adjustment Lever
PLBRAKES 5 - 35
REMOVAL AND INSTALLATION (Continued)

(2) Assemble front and rear brake shoe assembly,
automatic adjuster screw and upper return spring
before installation on brake support plate.
(3) Install the pre-assembled brake shoes, auto-
matic adjuster screw and upper return spring on the
brake support plate (Fig. 88).
(4) Install the wave washer on the pin of park
brake lever.
(5) Install pin on park brake lever into hole in rear
brake shoe assembly (Fig. 91).
(6) Install both brake shoe, to brake support plate,
hold down pins and clips (Fig. 85).
(7) Install the lower brake shoe to anchor plate
return spring (Fig. 86).(8) Install the automatic adjustment lever, on the
front brake shoe of the rear wheel brake assembly
(Fig. 84).
(9) Install the automatic adjustment lever to front
brake shoe assembly spring (Fig. 83).
(10) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(11) Install the rear brake drums on the hubs.
(12) Adjust rear brake shoes per Adjusting Rear
Brakes procedure in the service adjustments section
of the service manual.
(13) Install the wheel and tire assembly.
(14) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(15) Road test vehicle. The automatic adjuster
will continue the brake adjustment during the road
test of the vehicle.
REAR BRAKE SHOE SUPPORT PLATE
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear tire and wheel assembly from
vehicle.
(3) Remove the dust cap (Fig. 92) from the rear
hub/ bearing.
(4) Remove the retaining nut (Fig. 93) holding the
rear hub/bearing to the spindle. Remove the hub/
bearing from the spindle.
(5) Remove the rear brake shoes from the brake
support plate. Refer to Rear Brake Shoes in the
Removal And Installation Section in this group of the
service manual for the proper brake shoe assembly
removal procedure.
Fig. 90 Shoe Contact Areas on Support Plate
Fig. 91 Park Brake Lever Pin Retaining Clip
Installation
Fig. 92 Hub/ Bearing Dust Cap
PLBRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)

(6) Disconnect the rear brake flex hose tube from
the wheel cylinder (Fig. 94).
(7) Remove park brake actuator lever from the
park brake cable.
(8) Position a 1/2 wrench over the retainer fingers
on the end of the parking brake cable (Fig. 95). Com-
press cable housing retaining fingers and start cable
housing out of support plate (Fig. 95). Remove
wrench when retainer is free from the park brake
cable mounting hole in the rear brake support plate.
Alternate method is to use a aircraft type hose clamp
over cable housing end fitting compressing the three
fingers.
(9) Remove the 4 brake support plate to knuckle
attaching bolt and washer assemblies. Separate
brake support plate from rear suspension knuckle.
INSTALL
(1) Install brake support plate and gasket on rear
suspension knuckle casting. Torque support plate toknuckle casting attaching bolts to 75 N´m (55 ft.
lbs.).
(2) Insert parking brake cable end fitting into
brake support plate.
(3) Hand start hydraulic brake hose tube fitting to
wheel cylinder. Torque tube nut to wheel cylinder fit-
ting to 17 N´m (145 in. lbs.).
(4) Attach parking brake cable to the parking
brake actuator.
(5) Install rear brake shoe assemblies on the brake
support plate. Refer to Rear Brake Shoes in the
Removal And Installation Section in this group of the
service manual for the proper brake shoe assembly
installation procedure.
(6) Install rear hub and bearing assembly on rear
spindle. Install aNEWhub and bearing assembly
retaining nut (Fig. 93). Torque hub and bearing
assembly retaining nut to 217 N´m (160 ft. lbs.).
Install dust cap.
(7) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(8) Install brake drum. Adjust and bleed service
brakes.
(9) After brake drums are installed, pump brake
pedal several times to do final adjustment of the
brake shoe assemblies.
(10) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
REAR BRAKE WHEEL CYLINDER
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
Fig. 93 Rear Hub/ Bearing Retaining Nut
Fig. 94 Brake Flex Hose Tube At Wheel Cylinder
Fig. 95 Removing Park Brake Cable From Support
Plate
5 - 38 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove rear brake drum.
(4) Remove rear brake shoe assemblies from the
brake support plate. Refer to Rear Brake Shoes in
the Removal And Installation Section in this group of
the service manual for the proper brake shoe assem-
bly removal procedure.
(5) If brake shoes are wet with grease or brake
fluid, remove and replace.
(6) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 96).
(7) Remove rear wheel cylinder attaching bolts
(Fig. 96).
(8) Remove rear wheel cylinder assembly from
brake support plate (Fig. 97).INSTALL
(1) Apply a small bead of silicone sealer around
the mating surface of the wheel cylinder to brake
support plate.
NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake shoe assemblies.
(2) Install wheel cylinder onto brake support plate.
Tighten the attaching bolts to 13 N´m (115 in. lbs.).
(3) Hand start hydraulic brake hose tube fitting to
wheel cylinder. Torque tube nut to 17 N´m (145 in.
lbs.).
(4) Install rear brake shoe assemblies on the brake
support plate. Refer to Rear Brake Shoes in the
Removal And Installation Section in this group of the
service manual for the proper brake shoe assembly
installation procedure.
(5) Install rear brake drum onto rear hub.
(6) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(7) Adjust the rear brakes. See Rear Drum Brake
Shoe Adjustment in the Adjustments section in this
group of the service manual.
(8) Bleed the entire brake system. See Bleeding
Brake System in Service Adjustments section in this
group of the service manual.
REAR HUB/BEARING
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual for
the required lifting procedure to be used for this
vehicle.
(2) Remove rear wheel and tire assembly.
(3) On vehicles equipped with rear drum brakes,
remove brake drum (Fig. 98) from rear hub/bearing
assembly. On vehicles equipped with rear disc
brakes, remove disc brake caliper from disc brake
adapter, and then remove rotor (Fig. 99) from hub/
bearing assembly.
(4) Remove the dust cap (Fig. 100) from the rear
hub/bearing.
(5) Remove the retaining nut (Fig. 101) mounting
the hub/bearing to the rear spindle.
(6) Remove the hub/bearing from the rear spindle
by pulling it off the end of spindle by hand.
Fig. 96 Brake Flex Hose At Wheel Cylinder
Fig. 97 Remove/Install Wheel Cylinder
PLBRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)

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)

(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)

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)