brake DODGE NEON 2000 Service Workshop Manual

ADJUSTER UNLOADING (UNLOCKING)
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster locking pin or pin punch.
(1) Be sure the rear parking brake cables are both
properly installed in the equalizer.
(2) 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. 36), 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.
(3) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(4) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(5) Fully apply the parking brake lever.(6) Install the center console and its mounting
screws.
(7) Remove the blocks from the tire and wheels.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE SHOE LININGS ARE MADE FROM ASBES-
TOS-FREE MATERIALS, SOME AFTERMARKET
BRAKE SHOE LININGS MAY CONTAIN ASBESTOS.
THIS SHOULD BE TAKEN INTO ACCOUNT WHEN
SERVICING A VEHICLE'S BRAKE SYSTEM. IT IS
POSSIBLE THAT AFTERMARKET BRAKE SHOES
MAY HAVE BEEN INSTALLED ON THE VEHICLE.
ALWAYS WEAR A RESPIRATOR WHEN CLEANING
BRAKE COMPONENTS; ASBESTOS CAN CAUSE
SERIOUS BODILY HARM SUCH AS ASBESTOSIS
AND CANCER. NEVER CLEAN BRAKE COMPO-
NENTS BY USING COMPRESSED AIR; USE ONLY A
VACUUM CLEANER SPECIFICALLY DESIGNED FOR
THE REMOVAL OF BRAKE DUST. IF A VACUUM
CLEANER IS NOT AVAILABLE, CLEAN BRAKE
PARTS USING ONLY WATER-DAMPENED SHOP
TOWELS. DO NOT CREATE BRAKE LINING DUST
BY SANDING THE BRAKE LININGS WHEN SERVIC-
ING A VEHICLE. DISPOSE OF ALL DUST AND DIRT
SUSPECTED OF CONTAINING ASBESTOS FIBERS.
USE ONLY SEALED AIRTIGHT BAGS OR CONTAIN-
ERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL PROTECTION AGENCY
(EPA), FOR HANDLING AND DISPOSING OF PROD-
UCTS CONTAINING ASBESTOS.
CAUTION: Use only MoparTbrake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash it off immediately with water.
CAUTION: During service procedures, grease or
any other foreign material must be kept off the cal-
iper assembly, surfaces of the brake rotor and
external surfaces of the hub. Avoid deformation,
scratching or nicking of the brake rotor and brake
shoe linings.
Fig. 36 Pin Punch Installed
1 ± PARKING BRAKE LEVER
2 ± PIN PUNCH
3 ± OUTPUT CABLE
PLBRAKES 5 - 23
SERVICE PROCEDURES (Continued)

BRAKE PEDAL
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
WITH AUTOMATIC TRANSAXLE
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Place the steering wheel and tires in the
STRAIGHT-AHEAD position. Using a steering wheel
holder, lock the steering wheel in place to keep it
from rotating (Fig. 37). This keeps the clockspring in
the proper orientation.
(3) Remove the steering column coupling retainer
pin, back off the pinch bolt nut, and remove the
steering column coupling pinch bolt (Fig. 38) (the
pinch bolt nut is caged to the coupling and is not
removable). Separate the upper and lower steering
column couplings.
(4) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 39) in a counterclock-
wise direction approximately 30 degrees.
(5) Pull the switch rearward and remove it from
its mounting bracket.
(6) Remove the clip securing the power brake
booster input rod to the brake pedal (Fig. 39).
Remove the input rod from the brake pedal.
(7) Remove the two upper nuts fastening the brake
pedal bracket to the power brake booster (Fig. 40).(8) Carefully pry the tie bar running between the
two upper booster mounting studs from its plastic
retaining fasteners.
(9) Remove the two remaining nuts fastening the
brake pedal bracket to the power brake booster (Fig.
40).
Fig. 37 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 38 Steering Column Couplings
1 ± STEERING COLUMN UPPER COUPLING
2 ± PINCH BOLT
3 ± STEERING COLUMN LOWER COUPLING
4 ± BRAKE PEDAL
5 ± NUT
6 ± RETAINER PIN
Fig. 39 Brake Lamp Switch
1 ± SWITCH
2 ± CLIP
3 ± BRAKE PEDAL
4 ± CONNECTOR
5 - 24 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(10) If the vehicle is equipped with antilock
brakes, carefully push the power brake booster for-
ward until the booster contacts the ABS ICU mount-
ing bracket.
(11) If the vehicle does not have antilock brakes,
carefully push the power brake booster forward one
to two inches being careful not to stretch the brake
lines from the master cylinder to the brakes.
(12) Remove the two nuts fastening the brake
pedal bracket to the instrument panel support (Fig.
40).
(13) Carefully remove the brake pedal assembly by
pulling the pedal bracket back toward the instru-
ment panel, releasing the bracket from the booster
studs. Next, tip the bracket down past the input rod,
guiding the rod through the gap left by the missing
brace removed in Step (8). Remove the brake pedal
assembly out from under the instrument panel.
(14) The pedal can be removed from it's bracket by
grinding off the peened end of the shaft, removing
the shaft, pedal and bushings. A service parts pack-
age is available to replace these items.
INSTALLATION
(1) If the pedal has been removed from it's
bracket, install the pedal, bushings and bolt-in-shaft
on the bracket using the available service parts pack-
age.
(2) Install the brake pedal assembly by tipping the
pedal bracket and guiding the power brake booster
mounting portion up past the booster input rod.
Guide the top of the bracket onto the studs protrud-
ing from the instrument panel support (Fig. 40), then
guide the booster mounting portion onto the power
brake booster mounting studs.(3) Push the power brake booster back into mount-
ing position from under the hood.
(4) Install the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
Install the nuts all the way, but do not tighten them
at this time.
(5) Install the two lower power brake booster
mounting nuts, but do not tighten them at this time.
(6) Place the tie bar running between the two
upper booster mounting studs onto the studs with
the long flat side facing upward and the curved side
downward.
(7) Install the two upper power brake booster
mounting nuts on their studs.
(8) Tighten all four nuts fastening the brake pedal
bracket to the power brake booster to a torque of 34
N´m (300 in. lbs.).
(9) Tighten the two nuts fastening the brake pedal
bracket to the instrument panel support to a torque
of 34 N´m (300 in. lbs.).
(10) Install the power brake booster input rod on
the pin mounted on the side of the brake pedal.
Install a new retaining clip on the end of the pin
(Fig. 39). Do not reuse the old clip.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it's fully extended posi-
tion.
(11) Hold the brake lamp switch firmly in one
hand. Then using the other hand, pull outward on
the plunger of the brake lamp switch until it has
ratcheted out to its fully extended position.
(12) Mount the brake lamp switch into the bracket
using the following procedure:
²Depress the brake pedal as far down as possible.
²Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
²When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30É to lock
the switch into place.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(13) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(14) Install the dash-to-lower coupling seal in
place over the lower coupling's plastic collar and
dash cover.
(15) Verify the front tires are still in the
STRAIGHT-AHEAD position.
Fig. 40 Brake Pedal Mounting
1 ± CLUTCH CABLE
2 ± BOOSTER MOUNTING NUTS
3 ± UPPER MOUNTING NUTS
PLBRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)

(16) Reconnect the steering column lower coupling
to the steering column upper coupling (Fig. 38).
Install the coupling pinch bolt an tighten the pinch
bolt nut to a torque of 28 N´m (250 in. lbs.). Install
the pinch bolt retainer pin.
(17) Remove the steering wheel holder (Fig. 37).
(18) While looking under the instrument panel at
the lower coupling, rotate the steering wheel back-
and-forth to verify that the lower coupling does not
squeak against the dash-to-coupling seal.
(19) Reconnect the battery negative terminal.
(20) Check the stop lamps to verify they are oper-
ating properly and not staying on when the pedal is
in the released position.
(21) Road test the vehicle to ensure proper opera-
tion of the brakes.
WITH MANUAL TRANSAXLE
REMOVAL
(1) Remove the instrument panel. Refer to the
INSTRUMENT PANELS AND SYSTEMS group in
this service manual for the required procedure.
(2) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 39) in a counterclock-
wise direction approximately 30 degrees.
(3) Pull the switch rearward and remove it from
its mounting bracket.
(4) Disconnect the clutch cable from the clutch
pedal spacer (Fig. 41).(5) Disconnect the wiring harness connector going
to the clutch pedal switches (Fig. 42).
(6) Remove the clip securing the power brake
booster input rod to the brake pedal (Fig. 39).
Remove the input rod from the brake pedal.
(7) Remove the four nuts fastening the brake pedal
bracket to the power brake booster (Fig. 40).
(8) Remove the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
(9) Remove the brake pedal assembly.
(10) The pedal can be removed from it's bracket by
grinding off the peened end of the shaft, removing
the shaft, pedal and bushings. A service parts pack-
age is available to replace these items.
INSTALLATION
(1) If the pedal has been removed from it's
bracket, install the pedal, bushings and bolt-in-shaft
on the bracket using the available service parts pack-
age.
(2) Install the brake pedal assembly onto the studs
extending down from the instrument panel support
and power brake booster (Fig. 40).
(3) Install the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
Install the nuts all the way, but do not tighten them
at this time.
Fig. 41 Clutch Cable Connection
1 ± SNAP RING
2 ± CLUTCH PEDAL SPACER
3 ± CLUTCH PEDAL
4 ± CLUTCH CABLE
Fig. 42 Wiring Harness Connector
1 ± UPSTOP SWITCH
2 ± CLUTCH PEDAL
3 ± INTERLOCK SWITCH
4 ± CONNECTOR
5 - 26 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Install the power brake booster mounting nuts.
Tighten the four nuts fastening the brake pedal
bracket to the power brake booster to a torque of 34
N´m (300 in. lbs.).
(5) Tighten the two nuts fastening the brake pedal
bracket to the instrument panel support to a torque
of 34 N´m (300 in. lbs.).
(6) Connect the clutch cable to the clutch pedal
spacer on the pedal (Fig. 41).
(7) Connect the wiring harness connector going to
the clutch pedal switches (Fig. 42).
(8) Install the power brake booster input rod on
the pin mounted on the side of the brake pedal.
Install a new retaining clip on the end of the pin
(Fig. 39). Do not reuse the old clip.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it's fully extended posi-
tion.
(9) Hold the brake lamp switch firmly in one hand.
Then using the other hand, pull outward on the
plunger of the brake lamp switch until it has ratch-
eted out to its fully extended position.
(10) Mount the brake lamp switch into the bracket
using the following procedure:
²Depress the brake pedal as far down as possible.
²Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
²When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30É to lock
the switch into place.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(11) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(12) Install the instrument panel. Refer to the
INSTRUMENT PANELS AND SYSTEMS group in
this service manual for the required procedure.
(13) Check the stop lamps to verify they are oper-
ating properly and not staying on when the pedal is
in the released position.
(14) Road test the vehicle to ensure proper opera-
tion of the brakes.
BRAKE LAMP SWITCH
REMOVAL
(1) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 43) in a counterclock-
wise direction approximately 30 degrees.(2) Pull the switch rearward and remove it from
its mounting bracket.
(3) Disconnect the wiring harness connector from
the brake lamp switch.
INSTALLATION
NOTE: Prior to installing brake lamp switch into
bracket, the plunger must be moved to its fully
extended position using the procedure in Step 1.
(1) Hold the brake lamp switch firmly in one hand.
Then using the other hand, pull outward on the
plunger of the switch until it has ratcheted out to its
fully extended position.
(2) Connect the wiring harness connector to the
brake lamp switch.
(3) Mount the brake lamp switch into the bracket
using the following procedure:
²Depress the brake pedal as far down as possible.
²Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
²When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30É to lock
the switch into place (Fig. 43).
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
Fig. 43 Brake Lamp Switch
1 ± SWITCH
2 ± CLIP
3 ± BRAKE PEDAL
4 ± CONNECTOR
PLBRAKES 5 - 27
REMOVAL AND INSTALLATION (Continued)

(4) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(5) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
MASTER CYLINDER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) With the engine not running, pump the brake
pedal 4-5 strokes until the pedal feel is firm.
(2) Disconnect the negative (ground) cable from
the battery and isolate the cable.
(3) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(4) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).(5) Disconnect the two brake tubes from the mas-
ter cylinder, and two brake tubes from the propor-
tioning valves (Fig. 45). Install plugs at all of the
open brake tube outlets on the master cylinder.
(6) Clean the area around where the master cylin-
der attaches to the power brake booster using a suit-
able brake cleaner such as MopartBrake Parts
Cleaner or an equivalent.
(7) Remove the two nuts attaching the master cyl-
inder to the power brake booster.
(8) Slide the master cylinder straight out of the
power brake booster.
(9) To remove the proportioning valves, unthread
each from the master cylinder.
INSTALLATION
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) If removed, install the proportioning valves in
their master cylinder ports. The valves are identical,
so they can be installed in either master cylinder
port going to the rear brakes. Make sure the O-rings
on the proportioning valves are new.
(2) Bleed the master cylinder before installing it
on the vehicle. Refer to MASTER CYLINDER
BLEEDING in SERVICE PROCEDURES within this
section of this service manual group.
(3) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.
Fig. 44 Master Cylinder
1 ± POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 ± POWER BRAKE BOOSTER
3 ± BRAKE FLUID PRESSURE SWITCH
4 ± MASTER CYLINDER
Fig. 45 Brake Tubes At 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 - 28 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Position the master cylinder on the studs of the
power brake booster, aligning the push rod of the
power brake booster with master cylinder piston
push rod. Carefully push the master cylinder onto
the studs until it contacts the face of the booster.
(5) Install the two master cylinder mounting nuts
and tighten each to a torque of 28 N´m (250 in. lbs.).
(6) Connect the four brake tubes to the master cyl-
inder and proportioning valve ports (Fig. 45). Tighten
all tube nuts to a torque of 17 N´m (145 in. lbs.).
(7) Connect the brake fluid level switch wiring
connector.
(8) Install the battery and clamp it in place.
(9) Connect the positive, then the negative
(ground) cable on the battery.
(10) Fill the master cylinder to the proper level.
(11) Road test the vehicle to ensure proper opera-
tion of the brakes.
BRAKE FLUID RESERVOIR
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: The master cylinder does not need to be
removed from the power brake booster for removal
and installation of the brake fluid reservoir.
REMOVAL
(1) Clean the master cylinder housing and brake
fluid reservoir exterior surfaces.
(2) Remove the brake fluid reservoir cap. Using a
clean syringe or siphoning tool, empty as much brake
fluid as possible from the reservoir.
(3) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).
(4) Remove the two plastic pins holding the reser-
voir to the master cylinder (Fig. 46).
(5) Lift the reservoir from the master cylinder
casting.
(6) Remove the grommets sealing the reservoir to
the master cylinder housing (Fig. 47).
INSTALLATION
(1) Install new sealing grommets in the master
cylinder housing (Fig. 47).
(2) Lubricate the sealing grommets with fresh
clean DOT 3 brake fluid. Place the reservoir in posi-
tion over the grommets making sure the filler hole is
towards the front of the vehicle. Seat the reservoir
into the grommets. While holding the reservoir firmly
against the grommets, install the two plastic pins
previously removed through their mounting holes
until they protrude out the other side of the master
cylinder reservoir (Fig. 46).
(3) Connect the brake fluid level switch wiring
connector (Fig. 44).
Fig. 46 Master Cylinder Reservoir
1 ± BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 ± RESERVOIR RETAINING PINS
3 ± SEAL
Fig. 47 Sealing Grommets
1 ± MASTER CYLINDER
2 ± GROMMETS
3 ± SEAL
PLBRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)

(4) Fill the reservoir with fresh clean DOT 3 brake
fluid. Refer to BRAKE FLUID LEVEL CHECKING
in the SERVICE PROCEDURES section in this sec-
tion of this service manual group.
BRAKE FLUID LEVEL SWITCH
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).
(2) Push together the retaining tabs holding the
brake fluid level switch in place in the brake fluid
reservoir (Fig. 46).
(3) Pull the brake fluid level switch out the other
side of the reservoir.
INSTALLATION
(1) Align the brake fluid level switch with its
mounting hole on the left side of the master cylinder
brake fluid reservoir. Push the switch into the fluid
reservoir until the switch retaining tabs are
expanded on the other side of the reservoir, locking it
in place (Fig. 46).
(2) Connect the brake fluid level switch wiring
connector (Fig. 44).
POWER BRAKE BOOSTER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate the cable.
(2) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(3) Remove the one nut and one bolt securing the
air cleaner box in place, then disconnect the wiring
harness connector at the air inlet sensor.
(4) Lift the air cleaner box upward enough to clear
its grommeted alignment post (Fig. 48), then move
the air cleaner box forward just enough to access the
battery tray mounting bolts.(5) Remove the 2 bolts, then the 2 nuts mounting
the battery tray to its bracket (Fig. 48). Remove the
battery tray.
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal 4-5 times while the engine is not run-
ning until a firm brake pedal is achieved.
(6) Remove the master cylinder. For the master
cylinder 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.
(7) If the vehicle is equipped with ABS, remove the
integrated control unit (ICU). Refer to INTEGRATED
CONTROL UNIT in REMOVAL AND INSTALLA-
TION within the ANTILOCK BRAKE SYSTEM sec-
tion of this service manual group for the procedure.
(8) If the vehicle is equipped with ABS, remove the
three bolts securing the ICU mounting bracket to the
frame rail.
(9) Disconnect the vacuum hoses from the check
valve on the power brake booster (Fig. 49), but do not
remove the check valve from power brake booster.
(10) Locate the brake pedal-to-power brake booster
input rod attachment under the instrument panel.
Position a small screwdriver (Fig. 50) under the cen-
ter tang of the retaining clip. Rotate the screwdriver
enough to allow the retaining clip tang to pass over
the end of the brake pedal pin. Remove the clip.
Fig. 48 Battery Tray Mounting
1 ± BATTERY TRAY MOUNTING NUTS
2 ± BATTERY TRAY MOUNTING BOLTS
3 ± AIR CLEANER BOX POST
5 - 30 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: Discard the used retaining clip, it is not
to be reused. Replace the clip with a new one on
reassembly.
(11) Remove the four nuts attaching the power
brake booster to the instrument panel (Fig. 51). The
nuts are accessible from under the instrument panel
in the area of the brake pedal bracket.
(12) Slide the power brake booster forward until
mounting studs clear the instrument panel. Turn the
booster sideways (Fig. 52), then remove it from the
vehicle.
INSTALLATION
(1) Turn the power brake booster sideways (Fig.
52), then install it into the engine compartment down
past the heater hoses and the strut tower. Rotate the
booster so its four mounting studs and input rod are
pointed straight toward the instrument panel. Slide
the input rod and studs through the instrument
panel and into mounting position.
(2) Under the instrument panel, install the four
power brake booster mounting nuts (Fig. 51). Tighten
the nuts to a torque of 34 N´m (300 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake booster input rod.
Fig. 49 Vacuum Check Valve
1 ± VACUUM CHECK VALVE
Fig. 50 Retaining Clip
1 ± BRAKE PEDAL
2 ± INPUT ROD
3 ± SCREWDRIVER
4 ± RETAINING CLIP
5 ± BRAKE PEDAL PIN
Fig. 51 Power Brake Booster Mounting
1 ± POWER BRAKE BOOSTER MOUNTING NUTS
2 ± BRAKE PEDAL
Fig. 52 Booster Removal/Installation
1 ± POWER BRAKE BOOSTER
PLBRAKES 5 - 31
REMOVAL AND INSTALLATION (Continued)

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)