ESP DODGE NEON 2000 Service Owner's Manual

(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 56). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Inspect and
discard these if they are worn or damaged.
(5) Remove the two brake caliper to steering
knuckle guide pin bolts (Fig. 57).
(6) Remove the disc brake caliper from the steer-
ing knuckle. The caliper is removed by first tipping
either the top (right side caliper) or bottom (left side
caliper) of the caliper away from the brake rotor,then pulling the caliper off the opposite end's caliper
slide abutment (on the knuckle) and brake rotor.
INSTALLATION
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Completely retract the caliper piston back into
the bore of the caliper.
(2) Lubricate both steering knuckle caliper slide
abutments with a liberal amount of MopartMulti-
purpose Lubricant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(3) Install the disc brake caliper (with pads) on the
brake rotor and steering knuckle. The left side cali-
per is installed by first sliding the top of the caliper
past the top caliper slide abutment on the steering
knuckle to hook the top edge of the caliper, then
pushing the lower end of the caliper into place
against the knuckle (Fig. 58). The right side caliper
is installed by first sliding the bottom edge of the cal-
iper past the lower caliper slide abutment on the
steering knuckle to hook the lower edge of the cali-
per, then pushing the top of the caliper into place
against the steering knuckle.
Fig. 56 Brake Hose Connection
1 ± CALIPER
2 ± HOSE
3 ± BOLT
Fig. 57 Caliper Mounting
1 ± RETAINER CLIP
2 ± BRAKE ROTOR
3 ± HUB
4 ± GUIDE PIN BOLTS
5 ± DISC BRAKE CALIPER
Fig. 58 Installing Left Caliper
1 ± SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 ± BRAKING DISC
3 ± DISC BRAKE CALIPER
4 ± STEERING KNUCKLE BRAKE ABUTMENT
5 - 34 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(7) Remove the outboard brake shoe from the cali-
per by prying the shoe retaining clip over the raised
area on the caliper. Slide the brake shoe down and
off of the caliper (Fig. 61).
(8) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip is out of the cavity
in the piston (Fig. 62) and remove the shoe.(9) Repeat the above procedure to the front brakes
on the other side of the vehicle.
INSTALLATION
(1) Begin on one side of the vehicle.
(2) Completely retract the caliper piston back into
the bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.
(3) Remove any protective paper from the noise
suppression gasket on both the inner and outer brake
shoes (if equipped).
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing the shoe in with the
thumbs (Fig. 63). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Slide the new outboard brake shoe onto the cal-
iper (Fig. 64).
(6) Lubricate both steering knuckle caliper slide
abutments with a liberal amount of MopartMulti-
purpose Lubricant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
Fig. 61 Removing Outboard Brake Shoe
1 ± CALIPER ASSEMBLY
2 ± HANGER WIRE
3 ± BRAKE FLEX HOSE
4 ± OUTBOARD BRAKE PAD
5 ± HUB/BEARING ASSEMBLY
6 ± STEERING KNUCKLE
7 ± SCREWDRIVER
Fig. 62 Removing Inboard Brake Shoe
1 ± INBOARD BRAKE SHOE
2 ± HANGER WIRE
3 ± CALIPER ASSEMBLY
4 ± RETAINING CLIP
5 ± PISTON
Fig. 63 Installing Inboard Brake Shoe
1 ± PISTON
2 ± BRAKE SHOE
3 ± CALIPER ASSEMBLY
5 - 36 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

DISC BRAKE CALIPER (REAR)
REMOVAL
(1) Using a brake pedal holding tool as shown (Fig.
66), 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 while the lines are discon-
nected.
(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) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 67). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Inspect and
discard these if they are worn or damaged.
(5) Remove the two caliper guide pin bolts (Fig.
68).
(6) Remove the caliper assembly from the brake
adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 69).
INSTALLATION
NOTE: Step (1) below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
Fig. 66 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. 67 Brake Hose Mounting
1 ± BRAKE HOSE
2 ± GUIDE PIN BOLTS
3 ± CALIPER
4 ± BOLT
Fig. 68 Caliper Mounting
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
5 - 38 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(5) Remove the caliper assembly from the brake
adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 71).
(6) Hang the brake caliper from rear strut using
wire or cord to prevent the weight of the caliper from
damaging the brake hose (Fig. 72).
(7) Remove the outboard brake shoe from the cali-
per by prying the brake shoe retaining clip over the
raised area on the caliper. Then slide the brake shoe
down and off of the brake caliper (Fig. 73).
(8) Pull the inboard brake shoe away from caliper
piston until the retaining clip is free from the cavity
in the piston (Fig. 74).
(9) 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) Completely retract the caliper piston back into
piston bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.
(3) Remove any protective paper from the noise
suppression gasket on both inner and outer brake
shoe assemblies (if equipped).
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing the shoe in with the
thumbs (Fig. 74). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Slide the outboard brake shoe onto the caliper
assembly (Fig. 73). Be sure the retaining clip is
squarely seated in the depressed areas on the caliper.
Fig. 71 Caliper Removal/Installation
1 ± BRAKING DISC
2 ± CALIPER ADAPTER
3 ± CALIPER
4 ± LOWER MACHINED ADAPTER ABUTMENT
Fig. 72 Supporting Caliper
1 ± FLEX HOSE
2 ± STRUT
3 ± WIRE HANGER
4 ± CALIPER ASSEMBLY
Fig. 73 Outboard Brake Shoe
1 ± CALIPER FINGERS
2 ± RETAINING CLIP
5 - 40 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

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)

(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)

(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)

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)

(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)

(3) Install the parking brake cable into the brake
support plate or the rear disc brake adapter. Be sure
the locking fingers on the cable retainer are
expanded once the cable is pushed all the way into
the support plate or brake adapter hole to ensure the
cable is securely held in place.
(4) On vehicles equipped with rear drum brakes:
²Install the parking brake cable on the parking
brake cable actuating lever (Fig. 99).
²Install the actuating spring to the brake shoe
and the brake adjustment lever (Fig. 100).
(5) On vehicles equipped with rear disc brakes:²Install the parking brake shoes actuator lever on
the parking brake cable (Fig. 102).
²Install the parking brake shoe assemblies on the
disc brake adapter (Fig. 98).
(6) Install the hub and bearing on the rear spin-
dle. Install a new hub and bearing retaining nut.
Tighten the retaining nut to a torque of 217 N´m
(160 ft. lbs.).
(7) Install the hub and bearing dust cap.
(8) On drum brake equipped vehicles, install the
rear brake drum.
(9) On vehicles equipped with rear disc brakes,
install the brake rotor, then the disc brake caliper
(Fig. 97). Install the two caliper guide pin bolts, then
tighten them to a torque of 22 N´m (192 in. lbs.).
(10) Install the rear tire and wheel assembly.
Tighten all wheel nuts to a torque of 135 N´m (100 ft.
lbs.).
(11) Lower the vehicle.
(12) Ensure that the seal grommet on the cable
that was installed from underneath is fully seated
into the floor pan.
(13) Route the parking brake cable under the car-
peting, up to parking brake cable retaining bracket
on floor pan. Install the parking brake cable through
the retaining bracket. Push the cable in until the
locking fingers on the cable retainer lock the cable
into place.
(14) Install the rear parking brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(15) 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 be in any posi-
tion when releasing the automatic adjuster.
(16) 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.
(17) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(18) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(19) Reposition the rear carpeting into place.
(20) Install the rear seat cushion. Be sure the seat
cushion is fully installed in the retainers on the floor
pan of the vehicle.
(21) Fully apply the parking brake lever.
Fig. 103 Parking Brake Cable Removal
1 ± CABLE RETAINER
2 ± OFFSET BOX WRENCH
3 ± PARKING BRAKE CABLE
Fig. 104 Cable At Tension Strut
1 ± TENSION STRUT MOUNTING BOLTS
2 ± TENSION STRUT
3 ± SPOOL BUSHING
4 ± NUT
5 ± PARKING BRAKE CABLE
5 - 52 BRAKESPL
REMOVAL AND INSTALLATION (Continued)