1999 DODGE NEON Service Repair Manual

PROPORTIONING VALVES
PROPORTIONING VALVE TESTING SPECIAL
TOOLS
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.
If a condition of premature rear wheel skid occurs
on a vehicle, the proportioning valve should always
be tested prior to it being replaced. This is due to the
fact that there are conditions other then a faulty pro-
portioning valve which can cause a premature rear
wheel skid.
Testing proportioning valve pressures on a vehicle
with or without ABS requires using the same special
tools.
There are 4 Pressure Fittings, Special Tool 6805
(Fig. 24) which are used for testing both rear propor-
tioning valves mounted in the master cylinder.
The pressure gauges used for testing the new in-
line proportioning valves on both non-ABS and ABS
brakes, is Pressure Gauge Set, Special Tool C-4007-A
currently used for testing the combination valve (Fig.
25).
PROPORTIONING VALVE TESTING NON ABS
BRAKE
If premature rear wheel skid occurs on hard brake
application, it could be an indication that a malfunc-
tion has occurred with one of the proportioning
valves.
One proportioning valve controls the right rear
brake, and the other proportioning valve controls the
left rear brake (Fig. 26). Therefore, a road test todetermine which rear brake slides first is essential.
Once the wheel which slides first is determined, use
the following procedure to diagnose the proportioning
valve.
The test procedure for a premature rear wheel skid
is the same for both rear wheel proportioning valves.
The pressure test fittings used for each proportioning
valve though are different due to proportioning valve
and brake tube nut thread sizes being unique for
each rear wheel. After road testing vehicle to deter-
mine which wheel skids first, the proper test fittings
required will have to be determined. Then follow the
procedure below for testing the required proportion-
ing valve.
(1) After road testing vehicle to determine which
rear wheel exhibits premature rear wheel skid, refer
to (Fig. 26) to determine which proportioning valve
needs to be tested.
Fig. 24 Proportioning Valve Pressure Test Fittings
Fig. 25 Proportioning Valve Pressure Test Gauge
Set
Fig. 26 Non-ABS Brakes Proportioning Valve
Location On Master Cylinder
5 - 16 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

(2) Remove hydraulic brake tube (Fig. 26) from
proportioning valve controlling the rear wheel of the
vehicle which has premature wheel skid.
(3) Remove proportioning valve from that outlet
port of the master cylinder.
CAUTION: Be sure the pressure test fitting being
installed into master cylinder, has the correct
thread sizes for installation into the master cylinder
and the installation of the proportioning valve.
(4) Install Pressure Test Fitting, Special Tool
6805-1 or 6805-2 (Fig. 27) into the outlet port of the
master cylinder, which the proportioning valve was
removed from.
(5) Install proportioning valve into pressure test
fitting installed in master cylinder outlet port (Fig.
27).
CAUTION: Be sure the pressure test fitting being
installed into proportioning valve, has the correct
thread sizes for installation into the proportioning
valve and installation of brake tube fitting.
(6) Install Pressure Test Fitting, Special Tool
6805-3 or 6805-4 (Fig. 27) into the outlet port of the
proportioning valve.
(7) Connect brake hydraulic tube onto the pressure
test fitting that was installed in proportioning valve
(Fig. 27).
(8) Install a Pressure Gauge, Special Tool
C-4007-A into each pressure test fitting (Fig. 28).
Bleed air out of hose from pressure test fitting to
pressure gauge, at pressure gauge to remove all
trapped air. hose.
(9) With the aid of a helper, apply pressure to the
brake pedal until reading on proportioning valve
inlet gauge, is at the pressure shown on the followingchart. Then check the pressure reading on the pro-
portioning valve outlet gauge. If proportioning valve
outlet pressure does not agree with value shown on
the following chart, when inlet pressure shown on
chart is obtained, replace the proportioning valve. If
proportioning valve is within pressure specifications
do not replace proportioning valve.
(10) Check rear wheel brake shoe linings for con-
tamination or for replacement brake shoes not meet-
ing OEM brake lining material specifications. These
conditions can also be a possible cause for a prema-
ture rear wheel skid.
(11) Install proportioning valve in master cylinder
and hand tighten until proportioning is fully
installed and O-ring seal is seated into master cylin-
der. Then torque proportioning valve to 40 N´m (30
ft. lbs.).
(12) Install brake tube on proportioning valve.
Torque tube nut to 17 N´m (145 in. lbs.) torque.
(13) Bleed the affected brake line. See Bleeding
Brake System in the Service Adjustments section of
the manual for proper bleeding procedure
PROPORTIONING VALVE TEST WITH ABS
BRAKES
If premature cycling of the rear brake ABS occurs
on hard brake application, it could be an indication
that a malfunction has occurred with one of the pro-
portioning valves.
One proportioning valve controls the right rear
brake, and the other proportioning valve controls the
left rear brake (Fig. 29). Therefore, a road test to
determine which rear brake slides first is essential.
Once the wheel which is skidding first is determined,
Fig. 27 Proportioning Valve Installation For
Pressure Testing
Fig. 28 Pressure Gauges Installed On Pressure Test
Fittings
PLBRAKES 5 - 17
DIAGNOSIS AND TESTING (Continued)

use the following procedure to diagnose the propor-
tioning valve.
The test procedure is the same for both rear pro-
portioning valves. After road testing the vehicle to
determine which wheel skids first, follow the proce-
dure below for testing the required proportioning
valve.
(1) Using a brake pedal holding tool as shown in
(Fig. 30) 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) Remove the chassis brake tubes (Fig. 29) from
the proportioning valve controlling the rear wheel of
the vehicle which has premature wheel skid.
NOTE: Removal of the brake flex hose routing
bracket is required to prevent bending the chassis
brake line going to the rear brake. If the routing
bracket is not removed the chassis brake line willneed to be bent when installing the proportioning
valve with the pressure test fittings installed.
(3) Remove the brake flex hose routing bracket
from the frame.
CAUTION: Be sure the pressure test fittings being
installed into the proportioning valve have the cor-
rect thread sizes and flares for installation into the
proportioning valve and for installation of the chas-
sis brake tubes.
(4) Install Pressure Test Fitting, Special Tool
6833±1 in the inlet port of the proportioning valve
(Fig. 31). Install Pressure Test Fitting, Special Tool
8187±2 in the outlet port of the proportioning valve
(Fig. 31). Tighten tube nuts to a torque of 17 N´m
(145 in. lbs.)
(5) Install the proportioning valve in the vehicle so
that Pressure Test Fitting, Special Tool 8187±2 in
installed on the chassis brake tube going to the rear
brake (Fig. 32). Install the chassis brake tube coming
from the HCU (Fig. 32) into Pressure Test Fitting,
Special Tool 6833±1. Tighten tube nut to a torque of
17 N´m (145 in. lbs.)
(6) Install a Pressure Gauge, Special Tool
C-4007-A into each pressure test fitting (Fig. 33).
Bleed air out of hose from pressure test fitting to
pressure gauge, at pressure gauge to remove all
trapped air.
Fig. 29 Proportioning Valve Location
Fig. 30 Brake Pedal Holding Tool
Fig. 31 Pressure Test Fittings Installed On
Proportioning Valve
Fig. 32 Proportioning Valve With Pressure Test
Fittings Installed
5 - 18 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

(7) With the aid of a helper, apply pressure to the
brake pedal until reading on proportioning valve
inlet gauge, is at the pressure shown on the following
chart. Then check the pressure reading on the pro-
portioning valve outlet gauge. If proportioning valve
outlet pressure does not agree with value shown on
the following chart, when inlet pressure shown on
chart is obtained, replace the proportioning valve. If
proportioning valve is within pressure specifications
do not replace proportioning valve.
(8) Check rear wheel brake shoe linings for con-
tamination or for replacement brake shoes not meet-
ing OEM brake lining material specifications. These
conditions can also be a possible cause for a prema-
ture rear wheel skid.
(9) Install proportioning valve in chassis brake
tube (Fig. 29). Tighten the proportioning valve to a
torque of 17 N´m (145 in. lbs.).
(10) Bleed the affected brake line. See Bleeding
Brake System in the Service Adjustments section of
the manual for proper bleeding procedure.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
RED BRAKE WARNING LAMP TEST
For diagnosis of specific problems with the red
brake warning lamp system, refer to Brake System
Diagnostics Chart 2, located in the Diagnosis And
Testing section in this group of the service manual.
STOP LAMP SWITCH TEST PROCEDURE
The required procedure for testing the stop lamp
switch is covered in Group 8H, Vehicle Speed Control
System in this service manual. The electrical circuit
tests for stop lamps is covered in Group 8W Rear
Lighting in this service manual.
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECK
Check master cylinder reservoir brake fluid level a
minimum of twice a year.
Master cylinder reservoirs are marked with the
wordsFULL AND MINindicating proper range of
the master cylinder fluid level (Fig. 34).
Fig. 33 Pressure Gauges Installed On Pressure Test
Fittings
BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS
Sales CodeBrake
System
TypeSplit
PointSlopeIdentifi-
cationInlet
PressureOutlet
Pressure
BRA 149
Disc/Drum400 psi 0.43 Black
Band1000 psi 600-700
psi
BRD 149
Disc/Disc300 psi 0.34 Bar Code
Band1000 psi 550-650
psi
BRF 149
Disc/Disc
W/ABS300 psi 0.34 Bar Code
Band1000 psi 550-650
psi
PLBRAKES 5 - 19
DIAGNOSIS AND TESTING (Continued)

CAUTION: Use only MoparTbrake fluid or an
equivalent 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.
If necessary, add specified brake fluid bringing
level to theFULLmark on the side of the master
cylinder brake fluid reservoir (Fig. 34).
BRAKE BLEEDING
NOTE: For bleeding the ABS hydraulic system, see
Bleeding Teves Mark 20 Hydraulic System in the
Service Procedures Section of the ABS Brake Sec-
tion in this group of the service manual.
CAUTION: Before removing the master cylinder
cover, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder.
PRESSURE BLEEDING
CAUTION: Use bleeder tank Special Tool C-3496-B
with required adapter for the master cylinder reser-
voir to pressurize the hydraulic system for bleed-
ing.
NOTE: Follow pressure bleeder manufacturer's
instructions for use of pressure bleeding equip-
ment.
When bleeding the brake system, some air may be
trapped in the brake lines or valves far upstream, as
much as ten feet from the bleeder screw (Fig. 35).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes to
ensure all the air gets out.The following wheel sequence for bleeding the
brake hydraulic system should be used to ensure
adequate removal of all trapped air from the hydrau-
lic system.
²Left rear wheel
²Right front wheel
²Right rear wheel
²Left front wheel
(1) Attach a clear plastic hose to the bleeder screw
starting at the right rear wheel and feed the hose
into a clear jar containing enough fresh brake fluid
to submerge the end of the hose (Fig. 36).
(2) Open the bleeder screw at leastone full turn
or more to obtain an steady stream of brake fluid
(Fig. 37).
(3) After 4 to 8 ounces of fluid has been bled
through the brake and an air-free flow is maintained
in the clear plastic hose and jar, close the bleeder
screw.
(4) Repeat the procedure at all the other remain-
ing bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been improved,
Fig. 34 Master Cylinder Fluid Level
Fig. 35 Trapped Air in Brake Line
Fig. 36 Proper Method for Purging Air From Brake
System (Typical)
5 - 20 BRAKESPL
SERVICE PROCEDURES (Continued)

enough fluid has not passed through the system to
expel all the trapped air. Be sure to monitor the fluid
level in the pressure bleeder. It must stay at the
proper level so air will not be allowed to reenter the
brake system through the master cylinder reservoir.
BLEEDING WITHOUT A PRESSURE BLEEDER
NOTE: Correct bleeding of the brakes hydraulic
system without the use of pressure bleeding equip-
ment will require the aid of a helper.
The following wheel sequence for bleeding the
brake hydraulic system should be used to ensure
adequate removal of all trapped air from the hydrau-
lic system.
²Left rear wheel
²Right front wheel
²Right rear wheel
²Left front wheel
(1) Attach a clear plastic hose to the bleeder screw
starting at the right rear wheel and feed the hose
into a clear jar containing enough fresh brake fluid
to submerge the end of the hose (Fig. 36).
(2) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened.
(3) Open the bleeder screw at least 1 full turn.
When the bleeder screw opens the brake pedal will
drop.
(4) Close the bleeder screw. Release the brake
pedal onlyafterthe bleeder screw is closed.
(5) Repeat steps 1 through 3, four or five times at
each bleeder screw. Then check the pedal for travel.
If pedal travel is excessive or has not been improved,
enough fluid has not passed through the system to
expel all the trapped air. Be sure to monitor the fluid
level in the master cylinder reservoir. It must stay at
the proper level so air will not be allowed to re-enter
the brake system.(6) Test drive vehicle to be sure brakes are operat-
ing correctly and that pedal is solid.
MASTER CYLINDER BLEEDING
(1) Clamp the master cylinder in a vise. Attach
Bleeding Tubes, Special Tool 6802 to the master cyl-
inder (Fig. 38) and (Fig. 39). Position so outlets of
Bleeding Tubes will be below surface of brake fluid
when reservoir is filled to its proper level.
(2) Fill brake fluid reservoir with brake fluid con-
forming to DOT 3 specifications such as Mopar or an
Equivalent.
(3) Using a wooden dowel per (Fig. 40). Depress
push rod slowly, and then allow pistons to return to
released position. Repeat several times until all air
bubbles are expelled.
(4) Remove bleeding tubes from master cylinder
outlet ports, plug outlet ports and install fill cap on
reservoir.
Fig. 37 Open Bleeder Screw at Least One Full Turn
Fig. 38 Bleeding Tubes Attached to ABS Master
Cylinder
Fig. 39 Bleeding Tubes Attached To Non-ABS
Master Cylinder
PLBRAKES 5 - 21
SERVICE PROCEDURES (Continued)

(5) Remove master cylinder from vise.
NOTE: Note: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der. But the master cylinder must have been bled
and filled upon installation.
BRAKE ROTOR MACHINING
BRAKE ROTOR MACHINING PROCEDURES
Any servicing of the rotor requires extreme care to
maintain the rotor to within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or pulsation,
the rotor should be resurfaced, refaced (Fig. 41) or
(Fig. 42) or replaced.
The following chart shows the location of measure-
ments and specifications when servicing the rotor.
NOTE: All rotors have markings for minimum
allowable thickness cast on an un-machined sur-
face of the rotor (Fig. 43).
This marking includes 0.76 mm (0.030 inch) allow-
able rotor wear beyond the recommended 0.76 mm
(0.030 inch) of rotor refacing.
The collets, shafts and adapters used on the brake
lathe and the bearing cups in the rotor MUST be
clean and free from any chips or contamination.
When mounting the rotor on the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
If the rotor is not mounted properly, the lateral
runout will be worse after refacing or resurfacing
than before.REFACING BRAKE ROTOR
Refacing of the rotor is not required each time the
brake pads are replaced.
When refacing a rotor the required 0.8 mm (0.003
inch) TIR (Total Indicator Reading) and 0.013 mm
(0.0005 inch) thickness variation limits MUST BE
MAINTAINED.Extreme carein the operation of
rotor turning equipment is required.
Fig. 40 Bleeding Master Cylinder
Fig. 41 Refacing Brake Rotor
Fig. 42 Resurfacing Brake Rotor (Final Finish)
5 - 22 BRAKESPL
SERVICE PROCEDURES (Continued)

The use of a double straddle cutter (Fig. 41) that
machines both sides of the rotor at the same time is
highly recommended.
RESURFACNG BRAKE ROTOR
This operation can be used when rotor surface is
rusty, has lining deposits or excessive lateral runout
or thickness variation is evident.
A sanding rotor attachment will remove surface
contamination without removing much rotor mate-
rial.
It will generally follow variations in thickness that
are in the rotor.
BRAKE DRUM MACHINING
Measure drum runout and diameter. If not to spec-
ification, reface drum. (Runout should not exceed
0.1524 mm or 0.006 inch). The diameter variation
(oval shape) of the drum braking surface must not
exceed either 0.0635 mm (0.0025 inch) in 30É or
0.0889 mm (0.0035 inch) in 360É.All brake drums are marked with the maximum
allowable brake drum diameter (Fig. 44).
PARK BRAKE LEVER AUTO ADJUSTER
MECHANISM
WARNING: THE AUTO ADJUSTING FEATURE OF
THIS PARKING BRAKE LEVER CONTAINS A CLOCK
SPRING LOADED TO APPROXIMATELY 20 POUNDS.
DO NOT RELEASE THE AUTO ADJUSTER LOCK-
OUT DEVICE BEFORE INSTALLING CABLES INTO
THE EQUALIZER. KEEP HANDS OUT OF AUTO
ADJUSTER SECTOR AND PAWL AREA. FAILURE TO
OBSERVE CAUTION IN HANDLING THIS MECHA-
NISM COULD LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARK BRAKE
LEVER OR CABLES IS REQUIRED, THE AUTO
ADJUSTER MUST BE RELOADED AND LOCKED
OUT.
Fig. 43 Minimum Brake Rotor Thickness Markings
(Typical)
BRAKE ROTOR REFINISHING LIMITS
Braking RotorRotor
ThicknessMinimum
Rotor
ThicknessRotor
Thickness
VariationRotor Run
Out*Rotor Micro
Finish
All Front Disc Brakes 20.13-19.87
mm
.792 -.782
in.18.4 mm
.724 in.0.013 mm
0.0005 in.0.13 mm
0.005 in.15-80 RMS
All Rear Disc Brakes 9.25-8.75
mm.364
-.344 in.7.25 mm
.285 in.0.013 mm
0.0005 in.0.13 mm
0.005 in.15-80 RMS
*
TIR Total Indicator Reading (Measured On Vehicle)
Fig. 44 Brake Drum Maximum Diameter
Identification
PLBRAKES 5 - 23
SERVICE PROCEDURES (Continued)