warning DODGE NEON 2000 Service Owner's Guide

CAUTION: Use only a new brake booster input rod-
to-brake pedal retaining clip to ensure proper
retainment.
(4) Connect the power brake booster input rod-to-
brake pedal pin. Install a new retaining clip. Do not
use the old clip.
(5) Connect all previously removed vacuum hoses
to the vacuum check valve (Fig. 49).
(6) If the vehicle is equipped with ABS, install the
ICU mounting bracket on the frame rail using its
three bolts. Tighten the nuts to a torque of 23 N´m
(200 in. lbs.).
(7) If the vehicle is equipped with ABS, reinstall
the ICU. Refer to INTEGRATED CONTROL UNIT in
REMOVAL AND INSTALLATION within the
ANTILOCK BRAKE SYSTEM section of this service
manual group for the procedure.
(8) Install the master cylinder. For the master cyl-
inder without ABS removal and installation proce-
dure, refer to MASTER CYLINDER in this section of
this service manual group. For the master cylinder
with ABS removal and installation procedure, refer
to MASTER CYLINDER in the ANTILOCK BRAKE
SYSTEM section of this service manual group.
(9) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 48). Tighten the two
bolts and nuts to a torque of 34 N´m (25 ft. lbs.).
(10) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 48).
(11) Install the one nut and one bolt securing the
air cleaner box in place, then connect the wiring har-
ness connector at the air inlet sensor.
(12) Install the battery and clamp it in place.
(13) Connect the positive, then the negative
(ground) cable on the battery.
(14) Adjust the stop lamp switch as necessary.
Refer to STOP LAMP SWITCH in the ADJUST-
MENTS section of this group.
(15) Bleed the base brake system.
(16) Road test the vehicle to ensure proper opera-
tion of the brakes.
PROPORTIONING VALVE
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 holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 53). This will isolate the master
cylinder from the brake hydraulic system and willnot allow the brake fluid to drain out of the master
cylinder reservoir.
(2) Disconnect the brake tube from the proportion-
ing valve requiring removal (Fig. 54).
(3) Unscrew the Proportioning valve from the mas-
ter cylinder.
Fig. 53 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. 54 Proportioning Valves On Master Cylinder
1 ± RIGHT FRONT BRAKE TUBE
2 ± LEFT FRONT BRAKE TUBE
3 ± LEFT REAR BRAKE TUBE
4 ± REAR PROPORTIONING VALVES
5 ± RIGHT REAR BRAKE TUBE
5 - 32 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Lubricate the O-ring on the proportioning
valve. Make sure the O-ring on the proportioning
valve is new.
(2) Install the proportioning valve in its master
cylinder port. Tighten the proportioning valve to a
torque of 40 N´m (30 ft. lbs.).
(3) Connect the brake tube to the proportioning
valve (Fig. 54). Tighten the tube nut to a torque of 17
N´m (145 in. lbs.).
(4) Remove the brake pedal holder (Fig. 53).
(5) Bleed the affected brake line. See BASE
BRAKE BLEEDING in the SERVICE PROCE-
DURES section in this service manual group.
(6) Road test the vehicle to ensure proper opera-
tion of the brakes.
BRAKES TUBES AND HOSES
NOTE: Brake hoses for each brake are unique and
are not interchangeable.
Always use Mopartreplacement brake hoses 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.
Use new copper seal washers on all connections
using banjo bolts and tighten all the fittings to their
specified torques.
Follow the procedures in the next three paragraphs
to reduce the potential for twisting the brake hose
during installation.
The flexible front hydraulic brake hose should
always be installed on the vehicle by first attaching
the banjo fitting to the disc brake caliper. Attach the
hose to the brake tubing before attaching it to the
front frame rail. Tighten all brake line fittings to the
specified torque.
On vehicles equipped with rear drum brakes,
loosely install the rear brake hose to the wheel cylin-
der first, then bolt the intermediate routing bracket
to the strut. Next, loosely install the hose to the steel
tube coming from the master cylinder. Attach the
hose bracket to the body. Finally, tighten the tube
nuts at each end of the brake hose.
On vehicles equipped with rear disc brakes, attach
the brake hose banjo fitting to the caliper first, then
loosely install the hose to the steel tube coming from
the master cylinder. Next, attach the brake hose
bracket to the body. Finally, tighten the tube nut at
the each of the end of the brake hose connecting to
the steel tube coming from the master cylinder.Only double wall 4.75 mm (3/16 in.) steel brake
line tubing with Nygal coating should be used for
replacement along with its special tube nuts. Care
must be taken when replacing brake tubing; to be
sure, use the proper bending and flaring tools, and
procedures to avoid kinking. Do not route the tubes
against sharp edges, moving components, or into hot
areas. All tubes should be properly attached with the
recommended retaining clips.
DISC BRAKE CALIPER (FRONT)
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.
55), 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 when the lines are opened.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the front tire and wheel assembly.
Fig. 55 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
PLBRAKES 5 - 33
REMOVAL AND INSTALLATION (Continued)

(4) Install the caliper guide pin bolts and tighten
them to a torque of 22 N´m (192 in. lbs.) (Fig. 57).
(5) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 56). Place one fitting
washer on each side of the hose fitting as the banjo
bolt is guided through the fitting. Install new wash-
ers if they are worn or damaged at all. Thread the
banjo bolt into the caliper and tighten it to a torque
of 48 N´m (35 ft. lbs.).
(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(7) Lower the vehicle.
(8) Remove the brake pedal holding tool.
(9) Bleed the caliper as necessary. Refer to BASE
BRAKE BLEEDING in the SERVICE PROCE-
DURES section in this service manual group.
(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
DISC BRAKE SHOES (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: Vehicles that are equipped with optional
Four-wheel-disc brake system use a different lining
material on the front disc brake shoes than vehicles
with front disc and rear drum brakes. When new
brake shoes are installed, be sure the brake shoes
for the correct type of brake system are used.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both front tire and wheel assemblies
from vehicle.
(3) Begin on one side of the vehicle.
(4) Remove the two brake caliper guide pin bolts
(Fig. 59).
(5) 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.
(6) Support the caliper using a wire or cord to pre-
vent the weight of caliper from damaging the brake
hose (Fig. 60). Do not let the caliper hang by the
brake hose.
Fig. 59 Caliper And Rotor Mounting
1 ± RETAINER CLIP
2 ± BRAKE ROTOR
3 ± HUB
4 ± GUIDE PIN BOLTS
5 ± DISC BRAKE CALIPER
Fig. 60 Supporting Caliper
1 ± WIRE HANGER
2 ± STEERING KNUCKLE
3 ± BRAKE DISC
4 ± DISC BRAKE CALIPER ASSEMBLY
5 ± BRAKE HYDRAULIC HOSE
PLBRAKES 5 - 35
REMOVAL AND INSTALLATION (Continued)

(6) Lubricate both adapter caliper slide abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(7) Starting with the lower end, carefully lower the
caliper and brake shoes over the brake rotor and
catch the caliper's bottom edge behind the caliper
slide abutment (Fig. 71). Rotate the top of the caliper
into mounting position on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(8) Carefully install the caliper guide pin bolts
(Fig. 70), then tighten them to a torque of 22 N´m
(192 in. lbs.).
(9) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(10) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to ensure
the vehicle has a firm brake pedal before moving the
vehicle.(13) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE ROTOR (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.
(3) Remove the rear disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (REAR) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove any clips retaining the brake rotor
(Fig. 70).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
INSTALLATION
NOTE: Inspect the disc brake shoes and parking
brake shoes before brake rotor installation.
(1) Install the rear brake rotor over the wheel
mounting studs and onto the hub (Fig. 70).
(2) Install rear disc brake caliper. Refer to DISC
BRAKE SHOES (REAR) in this REMOVAL AND
INSTALLATION section of this service manual
group.
(3) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(4) Adjust the parking brake shoes as necessary.
Refer to ADJUSTMENTS in this section of this ser-
vice manual group.
(5) Lower the vehicle.
(6) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
DRUM BRAKE WHEEL CYLINDER (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
Fig. 74 Inboard Brake Shoe
1 ± RETAINING CLIP
2 ± INBOARD SHOE
PLBRAKES 5 - 41
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)

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)

(22) Install the center console and its mounting
screws.
(23) Remove the blocks from the tires and wheels.
PARKING BRAKE SHOES (REAR DISC BRAKE)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS 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 the rear tire and wheel assembly.
(3) Remove the rear disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (REAR) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove rear brake rotor.
(5) Remove the dust cap from the rear hub and
bearing.
(6) Remove the rear hub and bearing assembly
retaining nut and washer.
(7) Remove the rear hub and bearing assembly
from the rear spindle.
(8) Remove the rear brake shoe assembly hold-
down clip (Fig. 105).(9) Turn the brake shoe adjuster wheel until the
adjuster is at shortest length.
(10) Remove the adjuster assembly from the park-
ing brake shoe assemblies (Fig. 106).
(11) Remove the lower shoe-to-shoe spring (Fig.
107).
Fig. 105 Rear Brake Shoe Hold-Down Clip
1 ± HOLD DOWN CLIP
Fig. 106 Parking Brake Shoe Adjuster Assembly
1 ± ADJUSTER
Fig. 107 Brake Shoe Lower Return Spring
1 ± LOWER SPRING
PLBRAKES 5 - 53
REMOVAL AND INSTALLATION (Continued)

CALIPER PISTON AND SEALS
CALIPER PISTON REMOVAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers.
(2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out.(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CALIPER SEAL REMOVAL
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(1) To disassemble the caliper, mount it in a vise
equipped with protective jaws.
(2) Remove the piston dust boot from the caliper
and discard (Fig. 118).
NOTE: Do not use a screw driver or other metal
tool for seal removal. Using such tools can scratch
the bore or leave burrs on the seal groove edges.
(3) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 119). Discard the old seal.
(4) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(5) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or
scoring should be honed. Use Caliper Hone, Special
Tool C-4095, or the equivalent to hone the bore. Do
Fig. 117 Correctly Installed Guide Pin Sleeve And
Bushing
1 ± CALIPER
2 ± BUSHING
3 ± SLEEVE
Fig. 118 Removing Caliper/Piston Dust Boot
1 ± CALIPER
2 ± SCREWDRIVER
3 ± BOOT
PLBRAKES 5 - 57
DISASSEMBLY AND ASSEMBLY (Continued)

ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION......65
ANTILOCK BRAKE SYSTEM COMPONENTS....66
ELECTRONIC BRAKE DISTRIBUTION.........69
TRACTION CONTROL SYSTEM..............70
HYDRAULIC CIRCUITS AND VALVE
OPERATION...........................71
DIAGNOSIS AND TESTING
SERVICE WARNINGS AND CAUTIONS........74
ABS GENERAL DIAGNOSTICS INFORMATION . . 74
ABS WIRING DIAGRAM INFORMATION........74
ABS VEHICLE TEST DRIVE.................74
ABS ELECTRONIC DIAGNOSIS..............75
TONE WHEEL...........................76
BRAKE FLUID CONTAMINATION.............76
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING............77ANTILOCK BRAKE SYSTEM BLEEDING.......77
MASTER CYLINDER BLEEDING.............77
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........78
MASTER CYLINDER......................78
INTEGRATED CONTROL UNIT...............79
WHEEL SPEED SENSOR (FRONT)...........81
WHEEL SPEED SENSOR (REAR)............83
DISASSEMBLY AND ASSEMBLY
INTEGRATED CONTROL UNIT...............84
SPECIFICATIONS
TONE WHEEL RUNOUT....................85
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE...........................85
BRAKE FASTENER TORQUE
SPECIFICATIONS.......................85
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION
This section covers the physical and operational
descriptions, and the on-car service procedures for
the Mark 20e Antilock Brake System (ABS) with
traction control. It is the only antilock brake system
available on this vehicle.
The purpose of the antilock brake system is to pre-
vent wheel lockup under braking conditions on virtu-
ally any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
The traction control system reduces wheel slip and
maintains traction at the driving speeds below 56
kph (35 mph) when road conditions call for traction
assistance. Refer to TRACTION CONTROL SYSTEM
in this section for more information.
Vehicles equipped with ABS use electronic brake
distribution (EBD) to balance front-to-rear braking
when the brakes are applied in the partial braking
range. Refer to ELECTRONIC BRAKE DISTRIBU-
TION in this section for more information.
There are a few performance characteristics of the
Mark 20e Antilock Brake System that may at first
seem abnormal, but in fact are normal. These char-
acteristics are described below.
NORMAL BRAKING
Under normal braking conditions, the ABS func-
tions the same as a standard base brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS BRAKING
ABS operation is available at all vehicle speeds
above 3±5 mph. If a wheel locking tendency is
detected during a brake application, the brake sys-
tem enters the ABS mode. During ABS braking,
hydraulic pressure in the four wheel circuits is mod-
ulated to prevent any wheel from locking. Each
wheel circuit is designed with a set of electric sole-
noids to allow modulation, although for vehicle sta-
bility, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into four control channels.
During antilock operation of the vehicle's brake sys-
tem, the wheels are controlled independently and are
on separate control channels.
The system can build, hold and release pressure at
each wheel, depending on signals generated by the
wheel speed sensors (WSS) at each wheel and
received at the controller antilock brake (CAB).
PLBRAKES 5 - 65