oil type DODGE NEON 1999 Service Repair Manual

ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
²SAE 30 = single grade engine oil.
²SAE 10W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use engine oils that are API Service Certified.
5W-30 and 10W-30 MOPAR engine oils conform to
specifications.
Refer to Group 9, Engine for engine oil specifica-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letterªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
FLUID CAPACITIES
FUEL TANK
All ..........................47.3 L (12.5 gal.)
ENGINE OIL W/FILTER CHANGE
All...........................4.25 L (4.5 qts.)
ENGINE OIL W/OUT FILTER CHANGE
All............................3.8 L (4.0 qts.)
COOLING SYSTEM
All*.............................6L(6.5 qts.)
*Includes heater and coolant recovery bottle
AUTOMATIC TRANSAXLE
NOTE: Overhaul Fill Capacity with Torque Con-
verter Empty
31TH .........................8.4 L (8.9 qts.)
31 TH (Fleet Vehicles).............8.7 L (9.2 qts.)
MANUAL TRANSAXLE
NV T350.................1.9-2.2 L (4.0-4.6 pts.)
POWER STEERING
All...........................0.95 L (2.0 pts.)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to. Use the schedule that best
describes these conditions.
Schedule ±A, lists maintenance recommended for
vehicles used for general transportation.
Schedule ±B, lists maintenance recommended for
vehicles used under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Frequent trailer towing
²Extensive idling
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)
Where time and mileage are listed, follow the
interval that occurs first.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery, clean, and tighten terminals as
required.
²Check fluid levels of coolant reservoir, power
steering and automatic transmission and add as
required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on schedule ± B (6,000 miles).
²Check coolant level, hoses and clamps.
²Check the manual transaxle fluid level.
²If the mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Replace engine oil filter.
²Lubricate front suspension ball joints.
²Adjust drive belt tension.
PLLUBRICATION AND MAINTENANCE 0 - 3

FRONT SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 10
DESCRIPTION AND OPERATION
BALL JOINT............................ 14
COIL SPRING........................... 14
COMPETITION PACKAGE SUSPENSION...... 13
FRONT SUSPENSION.................... 11
FRONT WHEEL HUB BEARING............. 14
LOWER CONTROL ARM.................. 13
McPHERSON STRUT..................... 13
STABILIZER BAR........................ 14
STEERING KNUCKLE.................... 13
WHEEL MOUNTING STUDS................ 14
DIAGNOSIS AND TESTING
BALL JOINT ASSEMBLY................... 16
HUB/BEARING.......................... 16
LOWER CONTROL ARM.................. 15
MCPHERSON STRUT ASSEMBLY........... 15
STABILIZER BAR........................ 16
STEERING KNUCKLE.................... 15
REMOVAL AND INSTALLATION
FRONT WHEEL MOUNTING STUDS......... 28LOWER CONTROL ARM.................. 21
MCPHERSON STRUT.................... 16
STABILIZER BAR........................ 23
STEERING KNUCKLE.................... 17
WHEEL BEARING....................... 25
DISASSEMBLY AND ASSEMBLY
BALL JOINT............................ 32
LOWER CONTROL ARM FRONT
ISOLATOR BUSHING................... 33
LOWER CONTROL ARM REAR ISOLATOR
BUSHING............................ 34
McPHERSON STRUT..................... 30
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 36
SPECIFICATIONS
FRONT SUSPENSION FASTENER
TORQUES............................ 36
SPECIAL TOOLS
FRONT SUSPENSION.................... 37
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: ONLY FRAME CONTACT HOISTING
EQUIPMENT CAN BE USED ON THIS VEHICLE. All
vehicles have a fully independent rear suspension.
The vehicles can not be hoisted using equipment
designed to lift a vehicle by the rear axle. If this
type of hoisting equipment is used, damage to rear
suspension components will occur.
CAUTION: At no time when servicing a vehicle,
can a sheet metal screw, bolt or other metal fas-
tener be installed in the shock tower to take the
place of an original plastic clip. Also, NO holes can
be drilled into the front shock tower in the area
shown in (Fig. 1), for the installation of any metal
fasteners into the shock tower.
Because of the minimum clearance in this area
(Fig. 1) installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failureof the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
2 - 10 SUSPENSIONPL

(Fig. 6). The rear of the lower control arm is mounted
to both the front crossmember and the frame rail of
the vehicle using a thru-bolt. The thru-bolt goes
through both the crossmember and rear lower control
arm bushing, threading directly into the frame rail of
the vehicle. The lower control arms are inter-con-
nected through a linked rubber isolated stabilizer
bar.
STABILIZER BAR
The stabilizer bar (Fig. 7) interconnects both front
lower control arms of the vehicle and is attached to
the front suspension cradle.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle to stabilize body roll.
Attachment of the stabilizer bar to the front sus-
pension cradle is through 2 rubber-isolator bushings
and bushing retainers (Fig. 7). The stabilizer bar to
lower control arm attachment is done utilizing a rub-
ber isolated stabilizer bar attaching link (Fig. 7). All
parts of the stabilizer bar are serviceable, and the
stabilizer bar to crossmember bushings are split for
easy removal and installation. The split in the stabi-
lizer bar to crossmember bushing must be positioned
toward the front of the vehicle, when the stabilizer
bar is installed on the vehicle.
FRONT WHEEL HUB BEARING
The front hub bearing used on this vehicle is a
Unit 1 type cartridge bearing.
The wheel bearing is serviced separately from the
front steering knuckle and front hub. The hub bear-
ing is held in the steering knuckle by an interference
press fit and a retaining plate which is bolted to the
front of the steering knuckle. Installation of the front
hub into the wheel bearing must be done after the
wheel bearing and retaining plate is installed in the
steering knuckle.The unit 1 wheel bearing is serviced only as a com-
plete assembly less the wheel hub. If the front wheel
bearing requires replacement, the hub must be
removed from the original wheel bearing and trans-
ferred to the replacement bearing.
COIL SPRING
Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service. During service procedures
when both springs are removed, mark springs to
ensure installation in original position. Each coil
spring comes with a plastic sleeve on the second coil
of the spring. This plastic sleeve is a noise insulator
for the coil spring.
NOTE: If coil springs require replacement, be sure
that the springs needing replacement, are replaced
with springs meeting the correct load rating for the
vehicle and its specific options.
BALL JOINT
The ball joint (Fig. 8) is pressed into the lower con-
trol arm and has a non-tapered stud with a notch for
steering knuckle clamp bolt clearance. The ball joint
stud is clamped and locked into the steering knuckle
leg using a pinch bolt. The ball joint used on this
vehicle is replaceable and if found defective can be
serviced as a separate component of the lower control
arm assembly.
WHEEL MOUNTING STUDS
If wheel attaching studs need to be replaced in the
hub and bearing assembly the studsCAN NOTbe
hammered out of the hub flange. If a stud is removed
by hammering it out of the bearing flange, damage to
the hub and bearing assembly will occur leading to
premature bearing failure.
Fig. 6 Lower Control Arm Assembly
Fig. 7 Stabilizer Bar And Components
2 - 14 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 39
DESCRIPTION AND OPERATION
COIL SPRING........................... 41
COMPETITION PACKAGE SUSPENSION...... 41
KNUCKLE............................. 41
LATERAL LINKS AND TENSION STRUTS...... 41
REAR SUSPENSION..................... 39
STABILIZER BAR........................ 41
STRUT................................ 41
DIAGNOSIS AND TESTING
KNUCKLE............................. 42
LATERAL LINKS......................... 42
STABILIZER BAR AND BUSHINGS........... 43
STABILIZER BAR ATTACHING LINKS......... 43
STRUT INSPECTION (ON VEHICLE)......... 42
TENSION STRUT........................ 42
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT................ 43REMOVAL AND INSTALLATION
COIL SPRING........................... 44
KNUCKLE............................. 46
LATERAL LINKS......................... 48
STABILIZER BAR........................ 45
STRUT ASSEMBLY...................... 43
DISASSEMBLY AND ASSEMBLY
STABILIZER BAR BUSHINGS............... 53
STRUT ASSEMBLY...................... 50
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 53
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS...................... 54
SPECIAL TOOLS
REAR SUSPENSION..................... 54
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: Only frame contact or wheel lift hoisting
equipment can be used on vehicles having a fully
independent rear suspension. Vehicles with inde-
pendent rear suspension can not be hoisted using
equipment designed to lift a vehicle by the rear
axle. If this type of hoisting equipment is used dam-
age to rear suspension components will occur.
NOTE: If a rear suspension component becomes
bent, damaged or fails, no attempt should be made
to straighten or repair it. Always replace with a new
component.
DESCRIPTION AND OPERATION
REAR SUSPENSION
The rear suspension system used on this vehicle is
a fully independent type rear suspension system (Fig.
1).A forged rear knuckle is bolted to each rear strut.
The movement of the rear knuckle is controlled lat-
erally using lateral links going from the front and
rear of the knuckle to the rear crossmember. Fore
and aft movement of the knuckle is controlled by a
tension strut.
The lateral links and tension strut have rubber iso-
lator bushings at each end. The lateral links are
attached to the rear crossmember and knuckle, using
a common bolt and nut assembly at each end. The
tension strut bolts to the bottom of the knuckle and
to a bracket attached to the floor pan of the vehicle.
The lateral links, tension strut and spindle are
normally replaced only when the part has been dam-
aged or when the vehicle has been involved in an
accident. If a suspension part has been damaged, be
sure to check the underbody dimensions of the car. If
the underbody dimensions are not correct, the frame
of the vehicle must be straightened, before replace-
ment suspension components are installed.
PLSUSPENSION 2 - 39

COMPETITION PACKAGE SUSPENSION
On vehicles that are equipped with the optional
competition package, special rear struts are used.
The rear struts used on a vehicle equipped with
the competition package are adjustable. The adjust-
able struts use a unique strut shaft which has an
adjustment rod through the center of it (Fig. 2). The
adjustment rod is used to adjust the compression
dampening of the strut. By increasing the compres-
sion dampening of the strut, the jounce reaction of
the strut is slowed down. This slowing down of the
jounce reaction of the strut, stiffens the suspension
thus improving the handling of the vehicle.
The compression dampening of the strut is
adjusted using the adjustment knob (Fig. 3) which is
supplied with the vehicle at the time of purchase.
STRUT
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around the
struts. The coil springs are contained between theupper mount of the strut assembly and a lower
spring seat on the body of the strut assembly.
The top of each strut assembly is bolted to the top
of the inner fender through a rubber isolated mount.
The bottom of the strut assembly attaches to the
rear knuckle using 2 thru-bolts and prevailing torque
nuts. Rear Caster and camber on this vehicle is a
fixed setting (net build) and is not required to be
adjusted as a normal procedure when performing an
alignment on this vehicle.
COIL SPRING
Rear coil springs are rated separately for each cor-
ner or side of the vehicle depending on optional
equipment and type of vehicle service. During service
procedures when both rear coil springs are removed,
mark the coil springs to ensure installation of the
springs in their original position.If coil springs
require replacement, be sure the springs need-
ing replacement, are replaced with springs
meeting the correct load rating for the vehicle
and its specific options.
STABILIZER BAR
The stabilizer bar interconnects both rear strut
assemblies and is attached to the rear frame rails of
the vehicle.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle to stabilize body roll.
Attachment of the stabilizer bar to the rear frame
rails of the vehicle is through 2 rubber-isolator bush-
ings and bushing retainers. The stabilizer bar to
strut assembly attachment is done utilizing a rubber
isolated stabilizer bar attaching link. All parts of the
stabilizer bar are serviceable, and the stabilizer bar
to frame rail isolator bushings are split for easy
removal and installation. The split in the stabilizer
bar to crossmember bushing must be positioned
toward the rear of the vehicle, when the stabilizer
bar is installed on the vehicle.
KNUCKLE
A forged rear knuckle bolts to each rear strut
assembly. The movement of the rear knuckle is con-
trolled laterally using two lateral arms attached to
the knuckle. The outboard ends of the two lateral
arms are mounted forward and rearward of the spin-
dle centerline, and inboard ends are mounted to the
rear crossmember. Fore and aft movement of the
knuckle is controlled by using a tension strut.
LATERAL LINKS AND TENSION STRUTS
The lateral arms and tension strut have rubber
isolator bushings at each end. The lateral arms are
attached to the rear crossmember and knuckle, using
Fig. 2 Adjustable Front Strut
Fig. 3 Adjustable Strut Adjustment Knob
PLSUSPENSION 2 - 41
DESCRIPTION AND OPERATION (Continued)

(7) Remove carpet (if required) from top of strut
tower. Then remove rubber dust shield (Fig. 8) from
top of strut tower, this will allow easier access to
upper strut mount attaching nuts.
(8) Loosen but do not remove the 4 upper strut
mount to strut tower attaching nuts (Fig. 9). Then
while supporting the strut assembly fully remove the
4 strut mount attaching nuts.
(9) Remove strut assembly from knuckle, by slid-
ing knuckle out of clevis bracket on strut assembly.
Then remove strut assembly from vehicle.
INSTALL
(1) Position strut assembly back into vehicle with
the 4 studs on strut mount assembly through holes
in strut tower of vehicle. Install the 4 strut mount to
body attaching nuts (Fig. 9) onto mount studs.
Torque the 4 strut mount to body attaching nuts to
34 N´m (300 in. lbs).(2) Install dust shield into hole on top of strut
tower (Fig. 8). Install carpeting back on top of rear
strut tower.
(3) Raise vehicle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
installation. Install and torque nuts while holding
bolts stationary in knuckle.
(4) Install knuckle assembly into clevis bracket on
strut assembly. Install the 2 clevis bracket to knuckle
assembly attaching bolts and nuts (Fig. 7). Torque
both clevis bracket to knuckle assembly attaching
nuts to 95 N´m (70 ft. lbs.).
(5) Install hydraulic flex hose bracket, on strut
assembly bracket (Fig. 6). Install and securely
tighten bolt attaching hose bracket to strut bracket.
If vehicle is equipped with Anti-Lock brakes, the
wheel speed sensor cable routing clip is also attached
to the strut assembly bracket.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat tightening sequence to full speci-
fied torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
(8) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
COIL SPRING
Coil springs are rated separately for each side of
vehicle depending on optional equipment and type of
service. During service procedures where both
springs are removed, mark springs (Chalk, Tape,
etc.) (Fig. 10) to ensure installation in original posi-
tion. If the coils springs require replacement.Be
sure that the springs needing replacement, are
replaced with springs meeting the correct load
and spring rate for the vehicle.
NOTE: During service procedures requiring
removal or installation of a coil spring with Spring
Compressor, Special Tool C-4838. It is required that
the first full top and bottom coil of the coil spring
be captured by the jaws of spring compressor (Fig.
10).
Replacement of the coil spring requires removal of
the strut assembly from the vehicle, and the disas-
sembly of the strut. Refer to strut assembly in the
removal and installation section in this group of the
service manual for the required removal and replace-
ment procedure for the strut assembly. Then refer to
Fig. 8 Dust Shield Removal From Strut Tower
Fig. 9 Strut Mount Attaching Nuts
2 - 44 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

strut assembly in the disassembly and assembly sec-
tion in this group of the service manual for the
required procedure to disassemble and assemble the
strut assembly for the removal of the coil spring.
STABILIZER BAR
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 both rear wheel and tire assemblies
from the vehicle.
(3) Remove rear stabilizer bar from the 2 stabilizer
bar to strut attaching links (Fig. 11).
(4) Rotate stabilizer bar down slightly to clear
attaching links.
(5) Remove the 2 stabilizer bar to rear frame rail
retainers (Fig. 12).(6) Remove stabilizer bar from vehicle.
STABILIZER BAR AND BUSHING INSPECTION
Inspect for broken or distorted retainers and bush-
ings. If bushing replacement is required, bushing can
be removed by opening slit in bushing and removing
bushing from around stabilizer bar. When bushings
are installed on stabilizer bar, bushings must be
installed with slit positioned on stabilizer bar so slit
will face rear of vehicle when stabilizer bar is
installed (Fig. 13).
INSTALL
(1) Install stabilizer bar and isolator bushings
back into the vehicle as an assembly. Position stabi-
lizer bar so it is centered in the vehicle and does not
contact other suspension components or vehicle body.
(2) Install the 2 stabilizer bar to frame rail retain-
ers into frame rail and loosely install both retainer
attaching bolts (Fig. 12).
(3) Position both stabilizer bar to strut assembly
attaching links on stabilizer bar. Install and securely
tighten the stabilizer bar attaching link to stabilizer
bar attaching nuts (Fig. 11).
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
Fig. 10 Identifying Coil Springs
Fig. 11 Sway Bar To Strut Attaching Link
Fig. 12 Sway Bar To Frame Rail Retainers
Fig. 13 Bushings Correctly Installed On Stabilizer
Bar
PLSUSPENSION 2 - 45
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STRUT ASSEMBLY:
To Body Attaching Nuts.......34N´m(300 in. lbs.)
Clevis Bracket To Knuckle
Nut/Bolt..................95N´m(70ft.lbs.)
Strut Assembly Shaft Nut.......75N´m(55ft.lbs.)
BRAKE SUPPORT PLATE:
To Knuckle Bolts..............68N´m(50ft.lbs.)
STABILIZER BAR:
Bushing Retainer To
Frame Bolt...............34N´m(300 in. lbs.)
To Strut Attaching Link Nut . . .34 N´m (300 in. lbs.)
TENSION STRUT:
Shaft Nut...................95N´m(70ft.lbs.)
Bracket To Body Attaching
Bolts.....................95N´m(70ft.lbs.)
LATERAL LINK:
Attaching Nut................95N´m(70ft.lbs.)
DISC BRAKE CALIPER:
To Adapter Mounting Bolt......22N´m(16ft.lbs.)
Brake Hose To Caliper
Mounting Bolt..............45N´m(35ft.lbs.)
Adapter To Knuckle
Mounting Bolt..............68N´m(50ft.lbs.)
BRAKE HOSE:
Bracket Mounting Bolt........23N´m(17ft.lbs.)
HUB AND BEARING:
To Knuckle Retaining Nut.....216 N´m (160 ft. lbs.)
Wheel Stud Lug Nuts
(All Wheel Types). . . .109-150 N´m (80-110 ft. lbs.)
SPECIAL TOOLS
REAR SUSPENSION
Compressor Strut Coil Spring C-4838
2 - 54 SUSPENSIONPL

(7) With the aid of a helper, apply pressure to the
brake pedal until reading on proportioning valve
inlet gauge, is at the pressure shown on the following
chart. Then check the pressure reading on the pro-
portioning valve outlet gauge. If proportioning valve
outlet pressure does not agree with value shown on
the following chart, when inlet pressure shown on
chart is obtained, replace the proportioning valve. If
proportioning valve is within pressure specifications
do not replace proportioning valve.
(8) Check rear wheel brake shoe linings for con-
tamination or for replacement brake shoes not meet-
ing OEM brake lining material specifications. These
conditions can also be a possible cause for a prema-
ture rear wheel skid.
(9) Install proportioning valve in chassis brake
tube (Fig. 29). Tighten the proportioning valve to a
torque of 17 N´m (145 in. lbs.).
(10) Bleed the affected brake line. See Bleeding
Brake System in the Service Adjustments section of
the manual for proper bleeding procedure.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
RED BRAKE WARNING LAMP TEST
For diagnosis of specific problems with the red
brake warning lamp system, refer to Brake System
Diagnostics Chart 2, located in the Diagnosis And
Testing section in this group of the service manual.
STOP LAMP SWITCH TEST PROCEDURE
The required procedure for testing the stop lamp
switch is covered in Group 8H, Vehicle Speed Control
System in this service manual. The electrical circuit
tests for stop lamps is covered in Group 8W Rear
Lighting in this service manual.
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECK
Check master cylinder reservoir brake fluid level a
minimum of twice a year.
Master cylinder reservoirs are marked with the
wordsFULL AND MINindicating proper range of
the master cylinder fluid level (Fig. 34).
Fig. 33 Pressure Gauges Installed On Pressure Test
Fittings
BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS
Sales CodeBrake
System
TypeSplit
PointSlopeIdentifi-
cationInlet
PressureOutlet
Pressure
BRA 149
Disc/Drum400 psi 0.43 Black
Band1000 psi 600-700
psi
BRD 149
Disc/Disc300 psi 0.34 Bar Code
Band1000 psi 550-650
psi
BRF 149
Disc/Disc
W/ABS300 psi 0.34 Bar Code
Band1000 psi 550-650
psi
PLBRAKES 5 - 19
DIAGNOSIS AND TESTING (Continued)