engine oil DODGE NEON 2000 Service Repair Manual

LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS............................. 1
MAINTENANCE SCHEDULES................. 3JUMP STARTING, TOWING, AND HOISTING..... 7
LUBRICANTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
PARTS AND LUBRICANT
RECOMMENDATIONS....................1
CLASSIFICATION OF LUBRICANTS............1
INTERNATIONAL SYMBOLS.................2FLUID CHECK/FILL POINTS AND
LUBRICATION LOCATIONS.................2
LUBRICATION POINT LOCATIONS............2
SPECIFICATIONS
FLUID CAPACITIES........................2
DESCRIPTION AND OPERATION
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
CLASSIFICATION OF LUBRICANTS
DESCRIPTION
Only lubricants bearing designations defined by
the following organization should be used to service a
DaimlerChrysler Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 1)
²National Lubricating Grease Institute (NLGI)
(Fig. 2)
SAE VISCOSITY RATING
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. These are specified with a dual
SAE viscosity grade which indicates the cold-to-hot
temperature viscosity range. Example SAE 5W-30 =
multiple grade engine oil.DaimlerChrysler Corporation only recommends
multiple grade engine oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 1) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler
Corporation.
Refer to Group 9, Engine for gasoline engine oil
specification.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 80W-90.
Fig. 1 API Symbol
PLLUBRICATION AND MAINTENANCE 0 - 1

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 3).
FLUID CHECK/FILL POINTS AND LUBRICATION
LOCATIONS
The fluid check/fill points and lubrication locations
are located in each applicable Sections.
LUBRICATION POINT LOCATIONS
Lubrication point locations are located in each
applicable Sections.
SPECIFICATIONS
FLUID CAPACITIES
Fuel Tank (approximate)....47.5 Liter (12.5 gal.)
Engine Oil ± With Filter....... 4.3Liter (4.5 qts.)
Engine Oil ± Without Filter.... 3.8Liter (4.0 qts.)
Cooling System ± Includes Heater & Coolant
Recovery Bottle*........... 6.2Liter (6.5 qts.)
Automatic Transaxle ± Estimated Service
Fill........................ 3.8L(4.0 qts.)
Automatic Transaxle ± 31 TH ± Overhaul Fill
Capacity with Torque Converter Empty . . . 8.4 L
(8.9. qts.)
Manual Transaxle ± NV T350........ 1.9to2.2L
(4.0 to 4.6 pts.)
*Capacities include 1 qt. for coolant reserve tank.
Fig. 2 NLGI Symbol
1 ± WHEEL BEARINGS
2 ± CHASSIS LUBRICATION
3 ± CHASSIS AND WHEEL BEARINGS
Fig. 3 International Symbols
0 - 2 LUBRICATION AND MAINTENANCEPL
DESCRIPTION AND OPERATION (Continued)

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES................3
SPECIFICATIONS
UNSCHEDULED INSPECTION................3SCHEDULE ± A...........................3
SCHEDULE ± B...........................4
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Extensive idling
²More than 50% of the driving is at sustained
high speeds during hot weather, above 90É F (32É C)
SPECIFICATIONS
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
every other interval on Schedule ± B (6,000 miles -
10 000 km).
²Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable group.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km) or at 12 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
PLLUBRICATION AND MAINTENANCE 0 - 3

30,000 Miles (48 000 km) or at 24 months
²Change the engine oil.
²Replace the engine oil filter.
²Lubricate the front suspension lower ball joint.
²Inspect the tie rod ends and boot seals.
²Adjust the drive belt tension.
²Replace the engine air cleaner element (fil-
ter).
²Replace the engine spark plugs
²Change the automatic transaxle fluid.
37,500 Miles (60 000 km) or at 30 months
²Change the engine oil.
²Replace the engine oil filter.
45,000 Miles (72 000 km) or at 36 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
²Adjust the drive belt tension.
²Flush and replace the engine coolant at 36
months, regardless of mileage.
52,500 Miles (84 000 km) or at 42 months
²Change the engine oil.
²Replace the engine oil filter.
²Flush and replace the engine coolant if not done
at 36 months.
60,000 Miles (96 000 km) or at 48 months
²Change the engine oil.
²Replace the engine oil filter.
²Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
²Lubricate the front suspension lower ball joints.
²Replace the drive belts.
²Replace the engine air cleaner element (fil-
ter).
²Replace the ignition cables.
²Replace the spark plugs.
²Change the automatic transaxle fluid.
67,500 Miles (108 000 km) or at 54 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
75,000 Miles (120 000 km) or at 60 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
²Flush and replace engine coolant if has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change the engine oil.
²Replace the engine oil filter.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change the engine oil.
²Replace the engine oil filter.
²Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
²Lubricate the front suspension lower ball joints.
²Inspect the front brake pads and rear brake lin-
ings.
²Adjust the drive belt tension.
²Replace the engine air cleaner element (fil-
ter).
²Replace the spark plugs.
²Inspect the serpentine drive belt, replace if nec-
essary. This maintenance is not required if the belt
was previously replaced.
²Change the automatic transaxle fluid.
97,500 Miles (156 000 km) or at 78 months
²Change the engine oil.
²Replace the engine oil filter.
105,000 Miles (168 000 km) or at 84 months
²Change the engine oil.
²Replace the engine oil filter.
²Replace the engine timing belt.
²Adjust the drive belt tension.
*This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Inspection and service should also be per-
formed anytime a malfunction is observed or sus-
pected. Retain all receipts.
SCHEDULE ± B
3,000 Miles (5 000 km)
²Change the engine oil.
6,000 Miles (10 000 km)
²Change the engine oil.
²Replace the engine oil filter.
9,000 Miles (14 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
0 - 4 LUBRICATION AND MAINTENANCEPL
SPECIFICATIONS (Continued)

12,000 Miles (19 000 km)
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km)
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter).Replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust the bands.
18,000 Miles (29 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
21,000 Miles (34 000 km)
²Change the engine oil.
24,000 Miles (38 000 km)
²Change the engine oil.
²Replace the engine oil filter.
27,000 Miles (43 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect thePCV valveand replace as neces-
sary.*
²Lubricate the front suspension lower ball joints.
²Adjust the drive belt tension.
²Replace theengine air cleaner element (fil-
ter).
²Replace thespark plugs
²Change the automatic transaxle fluid/filter and
adjust bands.
33,000 Miles (53 000 km)
²Change the engine oil.
36,000 Miles (58 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
²Flush and replace the engine coolant.
39,000 Miles (62 000 km)
²Change the engine oil.
42,000 Miles (67 000 km)
²Change the engine oil.
²Replace the engine oil filter.
45,000 Miles (72 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
²Inspect theengine air cleaner element (fil-
ter).Replace as necessary.*
²Adjust the drive belt tension.
²Change the automatic transaxle fluid/filter and
adjust bands.
48,000 Miles (77 000 km)
²Change the engine oil.
²Replace the engine oil filter.
51,000 Miles (82 000 km)
²Change the engine oil.
²Flush and replace the engine coolant.
54,000 Miles (86 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
57,000 Miles (91 000 km)
²Change the engine oil.
60,000 Miles (96 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect thePCV valveand replace if neces-
sary.*
²Lubricate the front suspension lower ball joints.
²Replace the drive belts.
²Replace theengine air cleaner element (fil-
ter).
²Replace theignition cables
²Replace thespark plugs
²Check and replace, if necessary, theengine tim-
ing belton 3.0 liter engines.
²Change the automatic transaxle fluid/filter and
adjust bands.
63,000 Miles (101 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
66,000 Miles (106 000 km)
²Change the engine oil.
²Replace the engine oil filter.
PLLUBRICATION AND MAINTENANCE 0 - 5
SPECIFICATIONS (Continued)

69,000 Miles (110 000 km)
²Change the engine oil.
72,000 Miles (115 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
75,000 Miles (120 000 km)
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter)and replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust bands.
78,000 Miles (125 000 km)
²Change the engine oil.
²Replace the engine oil filter.
81,000 Miles (130 000 km)
²Change the engine oil.
²Flush and replace the engine coolant.
²Inspect the front brake pads and rear brake lin-
ings.
84,000 Miles (134 000 km)
²Change the engine oil.
²Replace the engine oil filter.
87,000 Miles (139 000 km)
²Change the engine oil.
90,000 Miles (144 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect front brake pads and rear brake linings
²Check thePCV valveand replace if necessary.
Not required if previously changed.*
²Lubricate the front suspension lower ball joint.
²Replace theengine air cleaner element (fil-
ter).²Replace thespark plugs
²Change the automatic transaxle fluid/filter and
adjust the bands.
93,000 Miles (149 000 km)
²Change the engine oil.
96,000 Miles (154 000 km)
²Change the engine oil.
²Replace the engine oil filter.
99,000 Miles (158 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
102,000 Miles (163 000 km)
²Change the engine oil.
²Replace the engine oil filter.
105,000 Miles (168 000 km)
²Replace theengine timing belt.
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter)and replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust the bands.
²Flush and replace the engine coolant.
* This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90É F (32É
C), using vehicle for police, taxi, limousine type
operation or trailer towing require the more fre-
quent transaxle service noted in Schedule ± B. Per-
form these services if vehicle usually operate under
these conditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCEPL
SPECIFICATIONS (Continued)

onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW
VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do notsecure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
Fig. 1 Jumper Cable Clamp Connections
1 ± BATTERY POSITIVE CABLE
2 ± POSITIVE JUMPER CABLE
3 ± TEST INDICATOR
4 ± BATTERY NEGATIVE CABLE
5 ± BATTERY
6 ± NEGATIVE JUMPER CABLE
7 ± ENGINE GROUND
Fig. 2 Recommended Towing Devices
1 ± WHEEL LIFT
2 ± FLAT BED
0 - 8 LUBRICATION AND MAINTENANCEPL
SERVICE PROCEDURES (Continued)

(4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 122).
(5) Position the dust boot into the counterbore of
the caliper assembly piston bore.
(6) Using a hammer and Installer, Special Tool
C-4689, and Handle, Special Tool C-4171, drive the
boot into the counterbore of the caliper (Fig. 123).
(7) Install the brake shoes.
(8) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Follow the installation pro-
cedure found in DISC BRAKE CALIPER in the
REMOVAL AND INSTALLATION section in this sec-
tion of this service manual group.
CLEANING AND INSPECTION
BRAKE TUBES AND HOSES
Flexible rubber hose is used at both front and rear
brakes. Inspection of brake hoses should be per-
formed whenever the brake system is serviced and
every 7,500 miles or 12 months, whichever comes
first (every engine oil change). Inspect hydraulic
brake hoses for severe surface cracking, scuffing,
worn spots or physical damage. If the fabric casing of
the rubber hose becomes exposed due to cracks or
abrasions in the rubber hose cover, the hose should
be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure.
Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.The steel brake tubing should be inspected period-
ically for evidence of corrosion, physical damage or
contact with moving or hot components of the vehi-
cle.
DISC BRAKES (FRONT)
BRAKE SHOES
Clean the front brake shoes and calipers with a
water-dampened cloth or with a brake cleaner. Do
not use a petroleum based product.
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary.
Remove the front disc brake shoes. Refer to DISC
BRAKE SHOES in the REMOVAL AND INSTALLA-
TION section in this section of this service manual
group.
The combined brake shoe and lining material
thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total
thickness of approximately 7.95 mm (5/16 inch) or
less, they should be replaced.
Replace both brake shoe assemblies (inboard and
outboard). It is necessary that both front wheel sets
be replaced whenever brake shoe assemblies on
either side are replaced.
Fig. 122 Installing Piston Into Caliper Bore
1 ± BOOT
2 ± PISTON
3 ± CALIPER
Fig. 123 Installing Dust Boot In Caliper Counterbore
1 ± HAMMER
2 ± SPECIAL TOOL C-4171
3 ± SPECIAL TOOL C-4689
4 ± CALIPER
PLBRAKES 5 - 59
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.....Standard
Hydraulic System.......Dual-Diagonally Split
BRAKE PEDAL:
Pedal Ratio..........................3.41
POWER BRAKE BOOSTER:
Make/Type..................Bosch/Vacuum
Mounting Studs.................. M8x1.25
Diaphragm Size/Type........ 205mmTandem
MASTER CYLINDER ASSEMBLY:
Type ........................Dual Tandem
Body Material...........Anodized Aluminum
Reservoir Material.............Polypropelene
MASTER CYLINDER BORE STROKE AND
SPLIT:
NonABS ..............22.23 mm x 34.0 mm
(0.875 in. x 1.34 in.)
ABS . . 23.82 mm x 34.0 mm (0.937 in. x 1.34 in.)
Displacement Split.................. 50/50MASTER CYLINDER FLUID OUTLET PORTS:
Tube Fitting Type...... SAE45ÉInverted Flare
W/ABS - Primary Tube Nut
Thread........................7/16 in.±24
W/ABS - Secondary Tube Nut
Thread........................ 3/8in.±24
W/O ABS - All Tube Nut Threads....7/16 in.±24
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting
Type................ SAE45ÉInverted Flare
All Tube Nut Threads............7/16 in.±24
PROPORTIONING VALVE:
Material.......................Aluminum
Function.....Hydraulic Pressure Proportioning
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts............... 17N´m(145 in. lbs.)
MASTER CYLINDER:
Mounting Nuts.......... 28N´m(250 in. lbs.)
POWER BRAKE BOOSTER:
Mounting Nuts.......... 34N´m(300 in. lbs.)
DISC BRAKE CALIPER:
Caliper Banjo Bolt......... 48N´m(35ft.lbs.)
Guide Pin Bolts.......... 22N´m(192 in. lbs.)
Bleeder Screw........... 15N´m(125 in. lbs.)
WHEEL CYLINDER (REAR):
Mounting Bolts.......... 13N´m(115in.lbs.)
Bleeder Screw............ 10N´m(80in.lbs.)
DRUM BRAKE SHOE SUPPORT PLATE
(REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
DISC BRAKE ADAPTER (REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
HUB AND BEARING (REAR):
Retaining Nut.......... 217N´m(160 ft. lbs.)
PARKING BRAKE:
Lever Mounting Nuts..... 28N´m(250 in. lbs.)
TIRE AND WHEEL:
Wheel Mounting Nut...........109±150 N´m
(80±110 ft. lbs.)
INTEGRATED CONTROL UNIT:
Mounting Bolts........... 11N´m(97in.lbs.)
CAB Mounting bolts........ 2N´m(17in.lbs.)
Bracket-to-Frame Rail Bolts.......... 23N´m
(200 in. lbs.)
WHEEL SPEED SENSOR:
Head Mounting bolt...... 12N´m(105 in. lbs.)
PLBRAKES 5 - 63

CAUTION: When removing a wheel speed sensor
from the knuckle, do not use pliers on the sensor
head. This may damage the sensor head. If the sen-
sor has seized, use a hammer and a punch to tap
the edge of the sensor head ear, rocking the sensor
side-to-side until free.
(5) Carefully, remove the sensor head from the
steering knuckle.(6) Remove the screw securing the wheel speed
sensor to the rear of the strut (Fig. 20). Remove the
wheel speed sensor.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Attach the wheel speed sensor to the strut
using the its mounting screw (Fig. 20).
(2) Install the wheel speed sensor head in the
steering knuckle (Fig. 19). Install the mounting bolt.
Tighten the mounting bolt to a torque of 12 N´m (105
in. lbs.).
(3) From the sensor bracket on the strut, loop the
sensor cable upward, then downward at the outside
of the frame rail. Install the speed sensor cable grom-
met onto the retaining bracket attached to the brake
hose on the outside of the frame rail.
(4) Loop the wheel speed sensor cable around the
bottom of the frame rail and connect it to the wiring
harness connector on the inside of the frame rail
(Fig. 18). Remember to push in the locking tab on the
connector.
(5) Install the tire and wheel assembly.
(6) Lower the vehicle.
(7) Road test vehicle to ensure proper operation of
the base brakes and ABS.
Fig. 18 Wiring Harness Connector
1 ± RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 ± RIGHT FRONT DRIVESHAFT
3 ± ENGINE OIL FILTER
Fig. 19 Wheel Speed Sensor
1 ± RIGHT FRONT WHEEL SPEED SENSOR
2 ± TONE WHEEL
Fig. 20 Wheel Speed Sensor At Strut
1 ± ABS WHEEL SPEED SENSOR ROUTING BRACKET (IF
EQUIPPED)
2 ± GROUND STRAP
3 ± GROUND STRAP SCREW
4 ± ABS SENSOR BRACKET SCREW (IF EQUIPPED)
5 - 82 BRAKESPL
REMOVAL AND INSTALLATION (Continued)