1999 DODGE NEON Service Repair Manual

(1) Remove screws attaching rear of center console
assembly to console bracket (Fig. 45) or (Fig. 46).
(2) Remove the 2 screws located in cup holders
(Fig. 47), attaching front of center console assembly
to console bracket.
(3) Raise park brake hand lever assembly as high
as it will go for required clearance to remove center
console.
(4) Remove center console assembly from vehicle.
(5) Lower park brake lever handle.
(6) Grasp park brake lever output cable by hand
and pull upward (Fig. 48). Continue pulling on cable
until a 3/16 in. drill bit can be inserted into handle
and sector gear of park brake mechanism (Fig. 48).
This will lock the park brake mechanism and take
tension off park brake cables.
RELEASING PARK BRAKE AUTO ADJUSTER
NOTE: The park brake lever can be in any position
when releasing the auto adjuster. To ease installa-
tion of center console, it is advisable to pull park
brake lever handle all the way up before removing
lockout pin
(1) Be sure rear park brake cables are properly
installed in the equalizer (Fig. 49).
(2) Pull park brake lever handle all the way up.
(3) Firmly grasp park brake lever locking pin (Fig.
50), and quickly remove it from the park brake lever
mechanism. This will allow the park brake lever
mechanism to correctly adjust the park brake cables.
(4) Install center console.
(5) Install the 4 console assembly attaching screws
(Fig. 45) or (Fig. 46).
(6) Cycle park brake lever once to position park
brake cables. Then return the park brake lever its
Fig. 45 Attaching Screws At Rear Of Center Console
W/O Arm Rest
Fig. 46 Attaching Screws At Rear Of Center Console
With Arm Rest
Fig. 47 Attaching Screws At Front Of Center
Console
Fig. 48 Locking Pin Installed In Park Brake
Mechanism
5 - 24 BRAKESPL
SERVICE PROCEDURES (Continued)

released position. Check the rear wheels of the vehi-
cle, they should rotate freely without dragging.
BRAKE TUBE REPAIR
Only double wall 4.75mm (3/16 in.) steel tubing
with Al-rich/ZN-AL alloy coating and the correct tube
nuts are to be used for replacement of a hydraulic
brake tube.
Care should be taken when repairing brake tubing,
to be sure the proper bending and flaring tools and
procedures are used, to avoid kinking. Do not route
the tubes against sharp edges, moving components or
into hot areas. All tubes should be properly attached
with recommended retaining clips.
Using Tubing Cutter, Special Tool C-3478-A or
equivalent, cut off damaged seat or tubing (Fig. 51).
Ream out any burrs or rough edges showing on
inside of tubing (Fig. 52). This will make the ends of
tubing square (Fig. 52) and ensure better seating offlared end tubing.PLACE TUBE NUT ON TUB-
ING BEFORE FLARING THE TUBING.
DOUBLE INVERTED TUBING FLARES
To make a double inverted tubing flare (Fig. 53)
and (Fig. 54). Open handles of Flaring Tool, Special
Tool C-4047 or equivalent. Then rotate jaws of tool
until the mating jaws of tubing size are centered
between vertical posts on tool. Slowly close handles
with tubing inserted in jaws but do not apply heavy
pressure to handle as this will lock tubing in place.
Fig. 49 Park Brake Cables Properly Installed In
Equalizer
Fig. 50 Removing Lockout Pin From Park Brake
Lever
Fig. 51 Cutting And Flaring Of Brake Fluid Tubing
Fig. 52 Brake Fluid Tube Preparation For Flaring
PLBRAKES 5 - 25
SERVICE PROCEDURES (Continued)

Place gauge (Form A) on edge over end of brake
tubing. Push tubing through jaws until end of tubing
contacts the recessed notch in gauge matching the
tubing size. Squeeze handles of flaring tool and lock
tubing in place. Place 3/16 inch plug of gauge (A)
down in end of tubing. Swing compression disc over
gauge and center tapered flaring screw in recess of
disc. Screw in until plug gauge has seated on jaws of
flaring tool. This action has started to invert the
extended end of the tubing. Remove gauge and con-
tinue to screw down until tool is firmly seated in tub-
ing. Remove tubing from flaring tool and inspect
seat. Refer to tube routing diagrams for proper brake
tube routing and clip locations. Replace any damaged
tube routing clips.
REMOVAL AND INSTALLATION
WHEEL AND TIRE ASSEMBLY
To install the wheel and tire assembly, first posi-
tion it properly on the mounting surface using the
hub pilot as a guide. Then progressively tighten the
lug nuts in the proper sequence (Fig. 55) to half of
the required torque. Finally tighten the lug nuts in
the proper sequence (Fig. 55) to 129 N´m (95 ft. lbs.).
Never use oil or grease on studs or nuts.
FRONT DISC BRAKE CALIPER
REMOVE
During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the braking rotor and caliper should
be done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this service manual for the required
lifting procedure for this vehicle.
(2) Remove the front wheel and tire assemblies
from this vehicle.
(3) Remove the 2 brake caliper to steering knuckle
guide pin bolts (Fig. 56).
(4) Remove caliper from steering knuckle, by first
rotating free end of caliper away from steering
Fig. 53 Double Inverted Brake Line Tubing Flare
Fig. 54 Double Wall Inverted Flare Connection
Fig. 55 Wheel Nut Tightening Sequence
Fig. 56 Caliper Guide Pin Bolts
5 - 26 BRAKESPL
SERVICE PROCEDURES (Continued)

knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
57).
(5) Support the disc brake caliper firmly using a
wire hanger (Fig. 58). This is required to prevent the
weight of the caliper from damaging the flexible
brake hose.
INSTALL
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Completely retract the caliper piston back into
the bore of the caliper.
(2) Lubricate both steering knuckle abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or equivalent.
(3) If removed, install the front rotor on the hub,
making sure it is squarely seated on face of hub.CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(4) Carefully position the brake caliper and brake
shoes on the steering knuckle by first hooking the
end of the caliper under the edge of the steering
knuckle as shown in (Fig. 59). Then rotate caliper
into position on the steering knuckle.
(5) Install the caliper guide pin bolts and tighten
to 18 to 20 N´m (192 in. lbs.) (Fig. 56).Extreme
caution should be taken not to cross thread the
caliper guide pin bolts.
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(8) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake pads.
Fig. 57 Removing Caliper Assembly From Steering
Knuckle
Fig. 58 Storing Disc Brake Caliper
Fig. 59 Installing Caliper Assembly On Steering
Knuckle
PLBRAKES 5 - 27
REMOVAL AND INSTALLATION (Continued)

FRONT DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED 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 CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the brake rotor and caliper should be
done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, it should be
replaced immediately.
During removal and installation of a wheel and
tire, use care not to strike the caliper.
NOTE: Before vehicle is moved after any brake
service work, pump the brake pedal several times
to insure the vehicle has a firm brake pedal.
NOTE: Starting with the 1998 model year, different
lining material is used on the disc brake shoes
depending on the type of brake system the vehicle
is equipped with. Vehicles equipped with standard
front disc and rear drum brakes use a new lining
material on the front disc brake shoes. Vehicles that
are equipped with optional 4 wheel disc brakes use
a new lining material on both the front and rear disc
brake shoes. When new brake shoes are installed,be sure brake shoes for the correct model year and
type of brake system the vehicle is equipped with
are used.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the front wheel and tire assemblies
from vehicle.
(3) Remove the 2 guide pin bolts (Fig. 60) mount-
ing the caliper to the steering knuckle.
(4) Remove brake caliper from steering knuckle, by
first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
61).
(5) Support caliper firmly to prevent weight of cal-
iper from damaging the flexible brake hose (Fig. 62).
Fig. 60 Caliper Guide Pin Bolts
Fig. 61 Removing Caliper From Steering Knuckle
5 - 28 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Remove brake rotor from hub by pulling it
straight off the wheel mounting studs (Fig. 63).
(7) Remove outboard brake shoe by prying the
shoe retaining clip over raised area on caliper. Then
slide the brake shoe down and off the caliper (Fig.
64).
(8) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip is out of the cavity
in the piston. (Fig. 65).
CALIPER INSPECTION
Check caliper for piston seal leaks (brake fluid in
and around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
or fluid leak is visible, disassemble caliper and
install a new seal and boot, (and piston if scored).
Refer to Caliper Disassembly And Re-Assembly Pro-
cedures in Disc Brake Caliper Service in this section
of the service manual.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.Replace if they are damaged, dry, or found to be brit-
tle. Refer to Guide Pin Bushing Service in Disc
Brake Caliper Service in this section of the service
manual.
INSTALL
(1) Completely retract caliper piston back into pis-
ton bore of caliper. This is required for caliper instal-
lation with new brake shoe assemblies.
(2) Lubricate both steering knuckle abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or equivalent.
(3) Install the front rotor on the hub, making sure
it is squarely seated on face of hub (Fig. 63).
(4) Remove the protective paper from the noise
suppression gasket on both the inner and outer brake
shoes (if equipped).
NOTE: Note: The inboard and outboard brake
shoes are not common (Fig. 66).
Fig. 62 Storing Caliper
Fig. 63 Removing/Installing Brake Rotor
Fig. 64 Removing Outboard Brake Shoe
Fig. 65 Removing Inboard Brake Shoe
PLBRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)

(5) Install the new inboard brake shoe into the cal-
iper piston by firmly pressing into piston bore with
thumbs (Fig. 67). Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
(6) Slide the new outboard brake shoe onto the cal-
iper (Fig. 68).
CAUTION: Use care when installing the caliper
onto the steering knuckle so the seals on the cali-
per guide pin bushings do not get damaged by the
steering knuckle bosses.
(7) Carefully position the brake caliper and brake
shoes over the rotor by hooking the end of the caliper
under the steering knuckle (Fig. 69). Then rotate cal-
iper into position on steering knuckle.
(8) Install the caliper guide pin bolts (Fig. 60) and
tighten to 18 to 20 N´m (192 in. lbs.).Extreme cau-
tion should be taken not to cross thread the
caliper guide pin bolts.
(9) Install the wheel and tire assembly.(10) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(11) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
REAR DISC BRAKE CALIPER
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the 2 caliper assembly to adapter
guide pin bolts (Fig. 70).
Fig. 66 Front Brake Shoe Identification
Fig. 67 Installing Inboard Brake Shoe
Fig. 68 Installing Outboard Brake Shoe
Fig. 69 Installing Caliper On Steering Knuckle
5 - 30 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Remove caliper assembly from adapter and
rotor by first rotating top of caliper assembly away
from adapter, and then lifting caliper assembly off
lower machined abutment on adapter (Fig. 71).
(5) Support caliper assembly firmly from rear strut
to prevent weight of caliper from damaging the flex-
ible brake hose (Fig. 72).
INSTALL
NOTE: Step 1 below is only required when install-
ing the disc brake caliper, after new brake shoes
have been installed.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments with a lib-
eral amount of MopartMultipurpose Lubricant, or
equivalent.(3) If removed, install the rear rotor on the hub
making sure it is squarely seated on the face of the
hub (Fig. 73).
CAUTION: Use care when installing caliper assem-
bly onto adapter so the guide pin bushings and
sleeves do not get damaged by the mounting
bosses on adapter.
Fig. 70 Caliper Assembly Guide Pin Bolts
Fig. 71 Removing Caliper Assembly From Adapter
Fig. 72 Storing Caliper
Fig. 73 Installing Rear Rotor
PLBRAKES 5 - 31
REMOVAL AND INSTALLATION (Continued)