clutch DODGE NEON 2000 Service Repair Manual

GROUP TAB LOCATORINIntroductionINaIntroduction0Lubrication and Maintenance2Suspension3Differential and Driveline5Brakes6Clutch7Cooling8ABattery8BStarting8CCharging System8DIgnition System8EInstrument Panel and Systems8EaInstrument Panel and Systems8FAudio System8GHorns8HVehicle Speed Control System8JTurn Signal and Flashers8KWindshield Wipers and Washers8LLamps8LaLamps8MRestraint System8NElectrically Heated Systems8OPower Distribution Systems8PPower Door Locks8QImmobilizer System8SPower Windows8TPower Mirrors8TaPower Mirrors8UChime Warning/Reminder System8WWiring Diagrams - LHD and RHD9Engine11Exhaust System13Frame and Bumpers14Fuel System19Steering21Transaxle22Tires and Wheels23Body24Heating and Air Conditioning24aHeating and Air Conditioning25Emission Control Systems

The in-line proportioning valves used on this vehi-
cle require special pressure fittings to test the pro-
portioning valves for proper proportioning valve
function. The pressure fittings are installed before
and after the proportioning valve being tested to ver-
ify proportioning valve is maintaining the required
hydraulic pressure to the rear wheel brake which it
controls.
The testing of proportioning valves for this vehicle,
if equipped with ABS, can be found in the
ANTILOCK BRAKE SYSTEM section.
PROPORTIONING VALVE TEST
The test procedure is the same for either rear pro-
portioning valve. After road testing the vehicle to
determine which wheel skids first, follow the proce-
dure below for testing the suspect proportioning
valve.
(1) Using a brake pedal holding tool as shown (Fig.
22), 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) Use the figure shown to determine which pro-
portioning valve needs to be tested (Fig. 21).
(3) Remove the hydraulic brake tube from the pro-
portioning valve controlling the rear wheel of the
vehicle that has premature wheel skid.
(4) Remove the proportioning valve from its outlet
port on the master cylinder.CAUTION: Be sure the pressure test fittings being
installed into master cylinder and proportioning
valve, have the correct thread sizes needed.
(5) Install the Brake Pressure Adapters, Special
Tool 8644 and 6805-3 onto the proportioning valve
(Fig. 23).
(6) Install the proportioning valve (with tools) back
into the outlet port on the master cylinder.
(7) Attach a Pressure Gauge, Special Tool
C-4007-A, to each pressure adapter (Fig. 24).
(8) Remove the brake pedal holding tool. Bleed any
air out of the pressure gauge hoses at the pressure
gauge.
(9) With the aid of a helper, apply pressure to the
brake pedal until the reading on proportioning valve
inlet gauge is at the target inlet pressure shown in
the BRAKE PROPORTIONING VALVE APPLICA-
TIONS AND PRESSURE SPECIFICATIONS table
Fig. 22 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. 23 Tools On Valve
1 ± PROPORTIONING VALVE
Fig. 24 Pressure Gauge Set
1 ± SPECIAL TOOL C-4007±A
5 - 16 BRAKESPL
DIAGNOSIS AND TESTING (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)

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)

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)

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)

(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)