DODGE NEON 2000 Service Repair Manual

REMOVAL
(1) Using a brake pedal holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 75). This will isolate the master
cylinder from the brake hydraulic system and will
not allow the brake fluid to drain out of the master
cylinder reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the rear tire and wheel assembly.
(4) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 76).
(5) Remove the rear brake drum.
(6) Remove the rear brake shoes from the brake
support plate. Refer to DRUM BRAKE SHOES in
this REMOVAL AND INSTALLATION section.
NOTE: If the brake shoes are wet with grease or
brake fluid, replace them.
(7) Remove the brake wheel cylinder attaching
bolts (Fig. 76).
(8) Remove the brake wheel cylinder from the
brake support plate (Fig. 77).
INSTALLATION
(1) Install a new O-ring at the mating surface of
the wheel cylinder-to-brake support plate (Fig. 77).NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake assembly.
(2) Install the wheel cylinder onto brake support
plate (Fig. 77). Tighten the attaching bolts to a
torque of 13 N´m (115 in. lbs.).
(3) Hand start the rear brake flex hose tube fitting
to wheel cylinder. Tighten the tube nut to a torque of
17 N´m (145 in. lbs.).
(4) Install the rear brake shoes on the brake sup-
port plate. Replace them as necessary.
(5) Install the rear brake drum onto the rear hub.
Fig. 75 Brake Pedal Holder
1 ± CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 ± THROTTLE PEDAL
3 ± BRAKE PEDAL HOLDING TOOL
4 ± STEERING WHEEL
5 ± DRIVER'S SEAT
6 ± BRAKE PEDAL
Fig. 76 Brake Flex Hose At Wheel Cylinder
1 ± BRAKE SUPPORT PLATE
2 ± WHEEL CYLINDER ATTACHING BOLTS
3 ± REAR BRAKE FLEX HOSE TUBE
4 ± WHEEL CYLINDER ASSEMBLY
Fig. 77 Remove/Install Wheel Cylinder
1 ± WHEEL CYLINDER
2 ± SUPPORT PLATE
3 ± O-RING
5 - 42 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(7) Adjust the rear brakes. Refer to ADJUST-
MENTS in this section of this service manual group.
(8) Lower the vehicle.
(9) Remove the brake pedal holder.
(10) Bleed the wheel cylinder as necessary. Refer
to BASE BRAKE BLEEDING in the SERVICE PRO-
CEDURES section in this service manual group.
(11) Road test the vehicle to make sure the brakes
operate correctly.
DRUM BRAKE SHOES (REAR)
NOTE: Before proceeding with this removal and
installation procedure, review the SERVICE WARN-
INGS AND CAUTIONS at the beginning of REMOVAL
AND INSTALLATION in this section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both rear tire and wheel assemblies
from the vehicle.
(3) Begin on one side of the vehicle.
(4) Remove the brake drum retaining clips (if
equipped) (Fig. 78).(5) Remove the brake drum (Fig. 78).
(6) Remove the automatic adjustment lever-to-
brake shoe spring (Fig. 79).
(7) Remove the automatic adjustment lever (Fig.
80) from the brake shoe.
(8) Remove the hold down clips and pins attaching
the leading and trailing brake shoes to the brake
support plate (Fig. 81).
(9) Remove the lower brake shoe-to-anchor plate
return spring (Fig. 82).
(10) Remove the parking brake lever pin-to-brake
shoe retaining clip (Fig. 83).
Fig. 78 Drum Brakes
1 ± DUST CAP
2 ± NUT
3 ± DRUM
4 ± HUB AND BEARING
5 ± WHEEL CYLINDER
6 ± SEAL
7 ± SUPPORT PLATE
8 ± BRAKE SHOES
9 ± RETAINER CLIP
Fig. 79 Automatic Adjustment Lever Spring
1 ± ADJUSTMENT LEVER
2 ± ADJUSTMENT LEVER TO BRAKE SHOE SPRING
3 ± HUB/BEARING
4 ± LEADING BRAKE SHOE
5 ± AUTOMATIC ADJUSTER SCREW
Fig. 80 Automatic Adjustment Lever
1 ± AUTOMATIC ADJUSTMENT LEVER
2 ± FRONT BRAKE SHOE ASSEMBLY
PLBRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

(11) Remove the leading and trailing brake shoes,
upper return spring and automatic adjuster screw
from the brake support plate as an assembly (Fig.
84).
(12) Disassemble the shoes completely once on the
bench.
(13) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
INSTALLATION
(1) Begin on one side of the vehicle.(2) Lubricate the eight shoe contact areas on the
support plate and anchor using MopartMulti-Pur-
pose Lubricant or equivalent (Fig. 85).
(3) Assemble the front and rear brake shoe assem-
bly, automatic adjuster screw, and upper return
spring before installation on the vehicle.
(4) Install the pre-assembled brake shoes, auto-
matic adjuster screw and upper return spring on the
brake support plate (Fig. 84).
(5) Install the wave washer on the pin of park
brake lever.
Fig. 81 Brake Shoe Hold Down Clips And Pins
1 ± HOLD DOWN CLIP
2 ± BRAKE SHOE
3 ± SUPPORT PLATE
4 ± PIN
Fig. 82 Brake Shoe To Anchor Plate Return Spring
1 ± ANCHOR PLATE
2 ± LOWER BRAKE SHOE RETURN SPRING
3 ± REAR BRAKE SHOE
4 ± FRONT BRAKE SHOE
5 ± BRAKE SUPPORT PLATE
Fig. 83 Parking Brake Lever Pin To Brake Shoe
Retaining Clip
1 ± RETAINING CLIP
2 ± PARK BRAKE LEVER PIN
3 ± PARK BRAKE LEVER
Fig. 84 Brake Shoe Removal/Installation
1 ± UPPER RETURN SPRING
2 ± AUTOMATIC ADJUSTER SCREW
3 ± TRAILING BRAKE SHOE
4 ± WHEEL MOUNTING STUDS
5 ± LEADING BRAKE SHOE
6 ± BRAKE SUPPORT PLATE
5 - 44 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Install the pin on the parking brake lever into
hole in rear brake shoe assembly (Fig. 86).
(7) Install both brake shoe-to-brake support plate
hold down pins and clips (Fig. 81).
(8) Install the lower brake shoe-to-anchor plate
return spring (Fig. 82).
(9) Install the automatic adjustment lever on the
leading brake shoe (Fig. 80).(10) Install the automatic adjustment lever-to-
brake shoe spring (Fig. 79).
(11) Adjust the brake shoes out until the drum
lightly drags on the shoes when it is installed. Do not
over-adjust the brakes.
(12) Install the brake drum (Fig. 78).
(13) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
(14) Install the tire and wheel assemblies. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(15) Adjust the rear brake shoes. Refer to
ADJUSTMENTS in this section of this service man-
ual group.
(16) Lower the vehicle.
(17) Road test vehicle stopping in both the forward
and reverse directions. The automatic adjuster will
continue to adjust the brakes during the road test of
the vehicle.
BRAKE DRUM (REAR)
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear tire and wheel assembly from
the vehicle.
(3) Remove the brake drum retaining clips (if
equipped) (Fig. 87).
Fig. 85 Shoe Contact Areas on Support Plate
Fig. 86 Parking Brake Lever Pin Retaining Clip
Installation
1 ± BRAKE SHOE ASSEMBLY
2 ± RETAINING CLIP
3 ± SCREWDRIVER
4 ± PARK BRAKE LEVER
5 ± PARK BRAKE LEVER PIN
Fig. 87 Drum Brakes
1 ± DUST CAP
2 ± NUT
3 ± DRUM
4 ± HUB AND BEARING
5 ± WHEEL CYLINDER
6 ± SEAL
7 ± SUPPORT PLATE
8 ± BRAKE SHOES
9 ± RETAINER CLIP
PLBRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)

(4) Remove the brake drum (Fig. 87).
NOTE: If the drum does not come off, further brake
clearance can be obtained by backing off the brake
automatic adjuster screw. Remove the rubber plug
from the top of brake support plate. Rotate the
automatic adjuster screw in an upward motion,
using a screwdriver.
INSTALLATION
NOTE: Before installing the drum, inspect the brake
shoe linings for wear, shoe alignment, and contam-
ination.
(1) Install the rear brake drum on rear hub and
bearing (Fig. 87).
(2) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(3) Adjust the rear brake shoes as necessary. Refer
to ADJUSTMENTS in this section of this service
manual group.
(4) Lower the vehicle.
DRUM BRAKE SHOE SUPPORT PLATE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Using a brake pedal holding tool as shown (Fig.
88), depress the brake pedal past its first one inch of
travel and hold it in this position. This will isolate
the master cylinder from the brake hydraulic system
and will not allow the brake fluid to drain out of the
master cylinder reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the rear tire and wheel assembly from
the vehicle.
(4) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 89).
(5) Remove the rear brake drum.
(6) Remove the dust cap (Fig. 90) from the rear
hub and bearing.
(7) Remove the nut (Fig. 91) holding the rear hub
and bearing to the spindle. Remove the hub and
bearing from the spindle.
(8) Remove the rear brake shoes from the brake
support plate. Refer to DRUM BRAKE SHOES in
this REMOVAL AND INSTALLATION section.(9) Remove the parking brake actuator lever from
the parking brake cable.
(10) Position a 1/2 inch wrench over the retainer
fingers on the end of the parking brake cable (Fig.
92). Compress the cable housing retaining fingers
with the wrench, then pull the cable housing out of
the support plate. Remove the wrench as the parking
brake cable retainer is freed from the mounting hole
in the brake support plate.
Fig. 88 Brake Pedal Holding Tool
1 ± CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 ± THROTTLE PEDAL
3 ± BRAKE PEDAL HOLDING TOOL
4 ± STEERING WHEEL
5 ± DRIVER'S SEAT
6 ± BRAKE PEDAL
Fig. 89 Brake Flex Hose At Wheel Cylinder
1 ± BRAKE SUPPORT PLATE
2 ± WHEEL CYLINDER ATTACHING BOLTS
3 ± REAR BRAKE FLEX HOSE TUBE
4 ± WHEEL CYLINDER ASSEMBLY
5 - 46 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(11) Remove the 4 brake support plate mounting
bolts and washers. Separate brake support plate
from rear suspension knuckle.
(12) Remove the brake wheel cylinder attaching
bolts.
(13) Remove the brake wheel cylinder from the
brake support plate.
INSTALLATION
(1) Install a new O-ring at 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 support plate.(2) Install the wheel cylinder onto brake support
plate. Tighten the attaching bolts to a torque of 13
N´m (115 in. lbs.).
(3) Install the brake support plate and gasket on
rear suspension knuckle. Tighten the support plate
mounting bolts to a torque of 75 N´m (55 ft. lbs.).
(4) Insert the parking brake cable into its mount-
ing hole in the brake support plate. Push the cable
housing in until the retainer's fingers lock into place.
(5) Hand start the brake flex hose tube fitting to
the wheel cylinder. Tighten the tube nut to a torque
of 17 N´m (145 in. lbs.).
(6) Attach the parking brake cable to the parking
brake actuator.
(7) Install the rear brake shoe assemblies on the
brake support plate.
(8) Install the rear hub and bearing assembly on
the spindle. Install a new hub and bearing retaining
nut (Fig. 91). Tighten the retaining nut to a torque of
217 N´m (160 ft. lbs.). Install dust cap.
(9) Install the brake drum.
(10) Install the wheel and tire assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(11) Adjust the rear brake shoes. Refer to
ADJUSTMENTS in this section of this service man-
ual group.
(12) Lower the vehicle.
(13) Remove the brake pedal holding tool.
(14) Bleed the wheel cylinder as necessary. Refer
to BASE BRAKE BLEEDING in the SERVICE PRO-
CEDURES section in this service manual group.
(15) Road test the vehicle to make sure the brakes
operate correctly.
Fig. 90 Hub And Bearing Dust Cap
1 ± HUB/BEARING ASSEMBLY
2 ± DUST CAP
Fig. 91 Rear Hub And Bearing Retaining Nut
1 ± RETAINING NUT
2 ± SPINDLE
3 ± HUB/BEARING ASSEMBLY
Fig. 92 Removing Park Brake Cable From Support
Plate
1 ± WRENCH
2 ± CABLE HOUSING RETAINER
3 ± PARK BRAKE CABLE
4 ± SUPPORT PLATE
PLBRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)

PARKING BRAKE LEVER
WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARKING
BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER ADJUSTMENT MECHANISM CAN BE
LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.
REMOVAL
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the wiring harness electrical connector
from the parking brake warning lamp switch on the
parking brake lever (Fig. 95).
(8) Remove the two nuts attaching the parking
brake lever to the vehicle (Fig. 95).
(9) Remove the parking brake lever from the vehi-
cle.
Fig. 93 Pin Punch Installed
1 ± PARKING BRAKE LEVER
2 ± PIN PUNCH
3 ± OUTPUT CABLE
Fig. 94 Parking Brake Cables At Equalizer
1 ± LEVER OUTPUT CABLE
2 ± EQUALIZER
3 ± REAR PARKING BRAKE CABLES
5 - 48 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place the parking brake lever on the mounting
studs on the vehicle floor. Install and tighten the two
mounting nuts to a torque of 28 N´m (250 in. lbs.)
(Fig. 95).
(2) Connect the wiring harness electrical connector
on the parking brake warning lamp switch (Fig. 95).
(3) Install both rear park brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(4) Ensure that the parking brake cables are cor-
rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster.
(5) Keeping your hands clear of the automatic
adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 93), then quickly
remove it from the parking brake lever mechanism.
This will allow the park brake lever mechanism to
automatically adjust the parking brake cables.
(6) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(7) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(8) Fully apply the parking brake lever.
(9) Install the center console and its mounting
screws.
(10) Remove the blocks from the tires and wheels.
PARKING BRAKE CABLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
The procedure below applies to either of the two
rear parking brake cables.
REMOVAL
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the rear seat cushion from the vehicle.
(8) Fold the rear carpeting forward to expose the
parking brake cables at the end of the rear floor.
(9) Install the box end of a 1/2 inch wrench over
the parking brake cable retainer (Fig. 96). Push the
wrench onto the retainer until the retainer fingers
are collapsed. From under the carpeting, grasp the
parking brake cable housing and pull cable straight
out of the bracket attached to the floor.
(10) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(11) Remove the rear tire and wheel assembly
from the vehicle.
(12) On vehicles equipped with rear drum brakes,
remove the brake drum. Refer to BRAKE DRUM in
this section of this service manual group.
(13) On vehicles equipped with rear disc brakes:
²Remove the disc brake caliper guide pin bolts,
then the caliper from disc brake adapter (Fig. 97).
²Hang the caliper out of the way using a wire
hanger or cord.
²Remove the brake rotor from the rear hub and
bearing.
(14) Remove the dust cap from the rear hub and
bearing.
Fig. 95 Parking Brake Lever
1 ± MOUNTING NUTS
2 ± PARKING BRAKE LEVER
3 ± PARKING BRAKE WARNING LAMP SWITCH CONNECTOR
PLBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

(15) Remove the hub and bearing retaining nut
from the knuckle spindle, then remove the hub and
bearing (Fig. 97).
(16) On vehicles equipped with rear disc brakes,
remove the upper return spring, both shoe hold-down
clips, then spread the rear parking brake shoes apart
at the top enough to clear the shoe anchor and
remove the parking brake shoes as an assembly from
the disc brake adapter (Fig. 98).
(17) To remove the rear parking brake cable from
the brake support plate on vehicles equipped with
rear drum brakes:
²Remove the parking brake cable from the park-
ing brake actuating lever (Fig. 99).
²Remove the actuating spring between the brake
shoe adjustment lever and the brake shoe (Fig. 100).
²Remove the parking brake cable from the rear
brake support plate. The parking brake cable can be
removed from brake support plate using a 1/2 inch
box wrench to compress the locking fingers on the
parking brake cable retainer (Fig. 101).
(18) To remove the rear parking brake cable from
the disc brake adapter on vehicles equipped with
rear disc brakes:
²Remove the parking brake actuating lever from
the parking brake cable (Fig. 102).
Fig. 96 Compressing Cable Retainer
1 ± CARPET ROLLED FORWARD
2 ± WRENCH
3 ± RIGHT REAR CABLE
4 ± REAR PARKING BRAKE CABLES
5 ± LEFT REAR CABLE
Fig. 97 Rear Disc Brakes
1 ± DISC BRAKE CALIPER
2 ± DISC BRAKE ADAPTER
3 ± GUIDE PIN BOLTS
4 ± HUB AND BEARING
5 ± BRAKE ROTOR
6 ± RETAINER CLIP
7 ± DUST CAP
8 ± NUT
Fig. 98 Parking Brake Shoes
1 ± UPPER RETURN SPRING
2 ± SHOE HOLD DOWN CLIPS
3 ± ADJUSTER
4 ± LOWER REAR SPRING
5 ± DISC BRAKE ADAPTER
5 - 50 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

²Remove the parking brake cable from the rear
disc brake adapter. The parking brake cable can be
removed from the disc brake adapter using a 1/2 inch
offset box wrench to compress the locking fingers on
the parking brake cable retainer (Fig. 103).
(19) Remove the nut, then the parking brake cable
routing bracket from the tension strut mounting bolt
(Fig. 104).
(20) Remove the parking brake cable and sealing
grommet from floor pan of the vehicle.
INSTALLATION
(1) From underneath push the parking brake cable
through the hole in the floor pan of the vehicle mak-
ing sure the cable sealing grommet is installed in the
floor pan as far as possible to insure a good seal.
(2) Attach the parking brake cable routing bracket
to the tension strut mounting bolt. Install and
tighten the mounting nut to a torque of 28 N´m (250
in. lbs.).
Fig. 99 Actuator Lever
1 ± PARK BRAKE ACTUATING LEVER
2 ± PARK BRAKE CABLE
3 ± BRAKE SHOE ASSEMBLIES
4 ± REAR SPINDLE
Fig. 100 Actuating Spring
1 ± BRAKE SHOE ADJUSTMENT LEVER
2 ± ADJUSTMENT LEVER ACTUATING SPRING
3 ± PARK BRAKE CABLE
Fig. 101 Parking Brake Cable Removal
1 ± PARK BRAKE CABLE
2 ± 1/288WRENCH
3 ± REAR BRAKE SUPPORT PLATE
4 ± PARK BRAKE CABLE RETAINER
Fig. 102 Parking Brake Actuator Lever
1 ± SHOE ACTUATOR LEVER
2 ± SHIELD MOUNTING SCREWS
3 ± REAR PARKING BRAKE CABLE
PLBRAKES 5 - 51
REMOVAL AND INSTALLATION (Continued)