1999 DODGE NEON tire type

(4) Carefully lower caliper and brake shoe assem-
blies over braking disc (rotor) reversing the required
removal procedure (Fig. 71). Make sure that the cal-
iper guide pin bolts, bushings and sleeves are clear of
the adapter bosses.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(5) Install caliper assembly guide pin bolts into
adapter and tighten (Fig. 70). Then torque both guide
pin bolts to 22 N´m (192 in. lbs.).
(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.
REAR 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 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.
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 assembly, 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 rear disc brake shoes.
Vehicles equipped with optional 4 wheel disc
brakes use a new lining material on the rear disc
brake shoes than prior model year vehicles
equipped with this brake system. 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 rear wheel and tire assemblies from
vehicle.
(3) Remove the 2 caliper assembly to adapter
guide pin bolts (Fig. 74).
(4) Remove caliper assembly from adapter and
rotor by first rotating top of caliper assembly away
Fig. 74 Caliper Assembly Guide Pin Bolts
5 - 32 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Disconnect the rear brake flex hose tube from
the wheel cylinder (Fig. 94).
(7) Remove park brake actuator lever from the
park brake cable.
(8) Position a 1/2 wrench over the retainer fingers
on the end of the parking brake cable (Fig. 95). Com-
press cable housing retaining fingers and start cable
housing out of support plate (Fig. 95). Remove
wrench when retainer is free from the park brake
cable mounting hole in the rear brake support plate.
Alternate method is to use a aircraft type hose clamp
over cable housing end fitting compressing the three
fingers.
(9) Remove the 4 brake support plate to knuckle
attaching bolt and washer assemblies. Separate
brake support plate from rear suspension knuckle.
INSTALL
(1) Install brake support plate and gasket on rear
suspension knuckle casting. Torque support plate toknuckle casting attaching bolts to 75 N´m (55 ft.
lbs.).
(2) Insert parking brake cable end fitting into
brake support plate.
(3) Hand start hydraulic brake hose tube fitting to
wheel cylinder. Torque tube nut to wheel cylinder fit-
ting to 17 N´m (145 in. lbs.).
(4) Attach parking brake cable to the parking
brake actuator.
(5) Install rear brake shoe assemblies on the brake
support plate. Refer to Rear Brake Shoes in the
Removal And Installation Section in this group of the
service manual for the proper brake shoe assembly
installation procedure.
(6) Install rear hub and bearing assembly on rear
spindle. Install aNEWhub and bearing assembly
retaining nut (Fig. 93). Torque hub and bearing
assembly retaining nut to 217 N´m (160 ft. lbs.).
Install dust cap.
(7) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(8) Install brake drum. Adjust and bleed service
brakes.
(9) After brake drums are installed, pump brake
pedal several times to do final adjustment of the
brake shoe assemblies.
(10) Install the wheel and tire assembly. 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.).
REAR BRAKE WHEEL CYLINDER
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
Fig. 93 Rear Hub/ Bearing Retaining Nut
Fig. 94 Brake Flex Hose Tube At Wheel Cylinder
Fig. 95 Removing Park Brake Cable From Support
Plate
5 - 38 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove rear brake drum.
(4) Remove rear brake shoe assemblies from the
brake support plate. Refer to Rear Brake Shoes in
the Removal And Installation Section in this group of
the service manual for the proper brake shoe assem-
bly removal procedure.
(5) If brake shoes are wet with grease or brake
fluid, remove and replace.
(6) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 96).
(7) Remove rear wheel cylinder attaching bolts
(Fig. 96).
(8) Remove rear wheel cylinder assembly from
brake support plate (Fig. 97).INSTALL
(1) Apply a small bead of silicone sealer around
the mating surface of the wheel cylinder to brake
support plate.
NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake shoe assemblies.
(2) Install wheel cylinder onto brake support plate.
Tighten the attaching bolts to 13 N´m (115 in. lbs.).
(3) Hand start hydraulic brake hose tube fitting to
wheel cylinder. Torque tube nut to 17 N´m (145 in.
lbs.).
(4) Install rear brake shoe assemblies on the brake
support plate. Refer to Rear Brake Shoes in the
Removal And Installation Section in this group of the
service manual for the proper brake shoe assembly
installation procedure.
(5) Install rear brake drum onto rear hub.
(6) Install the wheel and tire assembly. 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.).
(7) Adjust the rear brakes. See Rear Drum Brake
Shoe Adjustment in the Adjustments section in this
group of the service manual.
(8) Bleed the entire brake system. See Bleeding
Brake System in Service Adjustments section in this
group of the service manual.
REAR HUB/BEARING
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual for
the required lifting procedure to be used for this
vehicle.
(2) Remove rear wheel and tire assembly.
(3) On vehicles equipped with rear drum brakes,
remove brake drum (Fig. 98) from rear hub/bearing
assembly. On vehicles equipped with rear disc
brakes, remove disc brake caliper from disc brake
adapter, and then remove rotor (Fig. 99) from hub/
bearing assembly.
(4) Remove the dust cap (Fig. 100) from the rear
hub/bearing.
(5) Remove the retaining nut (Fig. 101) mounting
the hub/bearing to the rear spindle.
(6) Remove the hub/bearing from the rear spindle
by pulling it off the end of spindle by hand.
Fig. 96 Brake Flex Hose At Wheel Cylinder
Fig. 97 Remove/Install Wheel Cylinder
PLBRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)

(4) Remove bleeding tubes from master cylinder
outlet ports, plug outlet ports and install fill cap on
reservoir.
(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.
INSTALL
CAUTION: When replacing the master cylinder on
a vehicle equipped with ABS, a NEW vacuum seal
MUST be installed in the power brake vacuum
booster. Use only the procedure detailed below for
installing vacuum seal into power brake vacuum
booster. Be sure old vacuum seal is removed from
power brake vacuum booster before attempting to
install new seal.
CAUTION: When lubricating master cylinder push
rod, use only Mopar Silicone Dielectric Compound.
Using any other type of grease or lubricant on the
push rod, will not provide adequate long term lubri-
cation of the push rod.
(1) Lubricate master cylinder push rod as indi-
cated in (Fig. 111) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(2) Install vacuum seal on master cylinder push
rod as shown in (Fig. 112) with notches on vacuum
seal pointing toward master cylinder housing. Then
slide vacuum seal onto master push rod until seal is
seated against master cylinder housing (Fig. 113)
before installing master cylinder on power brake vac-
uum booster.CAUTION: If vehicle is equipped with ABS, be sure
old vacuum seal is removed from power brake vac-
uum booster before attempting to install master cyl-
inder and NEW vacuum seal. If vacuum seal is not
removed, refer to Master Cylinder Removal in this
section of the service manual for required vacuum
seal removal procedure.
(3) Position master cylinder on studs of power
brake unit, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(4) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 106) and torque to 28 N´m
(250 in. lbs.) torque.
(5) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 104) and (Fig. 105).
Torque all tube nuts to 17 N´m (145 in. lbs.) torque.
Fig. 111 Lubricating Master Cylinder Push Rod
Fig. 112 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 113 Vacuum Seal Positioned For Installing
Master Cinder
PLBRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

(9) InstallA NEWhub and bearing assembly
retaining nut. Torque the hub and bearing assembly
retaining nut to 168 N´m (124 ft. lbs.).
(10) Install hub and bearing assembly dust cap.
(11) Install rear rotor.
(12) Install rear disc brake caliper on the adapter
(See Brake Shoe Removal).
(13) Install wheel and tire assemblies.
(14) Tighten wheel stud nuts to 129 N´m (95
ft.lbs.).
STOP LAMP SWITCH
REMOVE
(1) Depress and hold the brake pedal while rotat-
ing stop lamp switch (Fig. 165) in a counter-clockwise
direction approximately 30 degrees.
(2) Pull the switch rearward and remove from its
mounting bracket.
(3) Disconnect wiring harness connector from stop
lamp switch.
INSTALL
NOTE: Prior to installing stop lamp switch into
bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
(1) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(2) Connect the wiring harness connector to the
stop lamp switch.(3) Mount the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then install switch in
bracket by aligning index key on switch with slot at
top of square hole in mounting bracket. When switch
is fully installed in bracket, rotate switch clockwise
approximately 30É to lock switch into bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If to much force is used, damage to the stop lamp
switch or striker (Fig. 165) can result.
(4) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger to
ratchet backward to the correct position.
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID RESERVOIR
NOTE: The master cylinder does not need to be
removed from the power brake vacuum booster for
replacement of the brake fluid reservoir.
(1) Clean master cylinder housing and brake fluid
reservoir.
(2) Remove the brake fluid reservoir cap. Using a
CLEANsyringe or equivalent type tool, empty as
much brake fluid as possible from the reservoir.
NOTE: Do not pry off using a tool, damage to res-
ervoir may result.
(3) Rock brake fluid reservoir from side to side
while pulling up to remove the reservoir from the
master cylinder housing (Fig. 166).
(4) Remove master cylinder housing to brake fluid
reservoir grommets.
Fig. 164 Front Hold Down Clip And Brake Shoe
Fig. 165 Stop Lamp Switch
PLBRAKES 5 - 57
REMOVAL AND INSTALLATION (Continued)

(3) Remove the rubber plug from the adjusting
hole in the brake shoe backing plate on both sides of
the vehicle.
(4)Driver (left) side park brake shoe adjust-
ment procedure.Insert a medium size screwdriver
through adjustment hole in backing plate. Position
the srewdriver against the starwheel on the park
brake shoe adjuster mechanism. Using the screw-
driver rotate the starwheeldownwarduntil a slight
drag is felt when turning the rear tire and wheel.
Then, using the screwdriver rotate the starwheel
upwardjust until the rear tire and wheel can be
rotated with no park brake shoe drag. From the
point where there is no more park brake drag rotate
the starwheelupwarda maximum of two additional
clicks. The park brake shoe to drum clearance is
know properly adjusted.
(5)Passenger (right) side park brake shoe
adjustment procedure.Insert a medium size
screwdriver through adjustment hole in backing
plate. Position the srewdriver against the starwheel
on the park brake shoe adjuster mechanism. Using
the screwdriver rotate the starwheelupwarduntil a
slight drag is felt when turning the rear tire and
wheel. Then, using the screwdriver rotate the star-
wheeldownwardjust until the rear tire and wheel
can be rotated with no park brake shoe drag. From
the point where there is no more park brake drag
rotate the starwheeldownwarda maximum of two
additional clicks. The park brake shoe to drum clear-
ance is know properly adjusted.
(6) Install the rubber plug in the adjusting hole on
the brake shoe backing plate on both sides of the
vehicle.
(7) Lower vehicle far enough to allow access the
park brake lever. The rear tires must not be on the
ground.
(8) Fully apply and release the park brakes two
times after adjusting the park brake shoes. Then
rotate both rear wheels to ensure that the park
brake shoes do not drag on the brake drum following
the application and release of the park brakes.
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. Anopen 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 ect.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
MASTER CYLINDER ASSEMBLY:
Type ...........................Dual Tandem
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE / STROKE
AND SPLIT:
NonABS ....21mmx32.6 mm (.875 in. x 1.28 in.)
ABS........21mmx32.7 mm (.874 in. x 1.29 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
ABS ..........Primary 3/8±24 Secondary 7/16±24
Non ABS . . .Primary Inboard And Outboard 7/16±24
Non ABS . . .Secondary Inboard And Outboard 3/8±23
Outlet Fitting Type.......SAE 45 É Inverted Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type.SAE 45 É Inverted Flare
BOOSTER:
Make/Type.........Bendix Vacuum W/&W/O ABS
Mounting Studs.....................M8x1.25
Type ..........................230 mm Single
Boost At 20 inches Of Manifold Vacuum. . . .4690 All
PROPORTIONING VALVE:
Material...........................Aluminum
Function........Hydraulic Pressure Proportioning
BRAKE PEDAL
Pedal Ratio.............................3.28
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To
HCU At HCU Ports........21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
PLBRAKES 5 - 67
ADJUSTMENTS (Continued)

integral part of the rear wheel hub and bearing
assembly. The speed sensor air gap on both applica-
tions is NOT adjustable.
The four Wheel Speed Sensors are serviced individ-
ually. The front Tone Wheels are serviced as an
assembly with the outboard constant velocity joint.
The rear Tone Wheels are serviced as an assembly
with the rear hub and bearing assembly.
Correct ABS system operation is dependent on
accurate wheel speed signals. The vehicle's wheels
and tires must all be the same size and type to gen-
erate accurate signals. Variations in wheel and tire
size can produce inaccurate wheel speed signals.
CONTROLLER ANTILOCK BRAKES (CAB)
The Controller Antilock Brakes (CAB) is a micro-
processor based device which monitors the ABS sys-
tem during normal braking and controls it when the
vehicle is in an ABS stop. The CAB is mounted to the
bottom of the HCU (Fig. 10). The CAB uses a 25 way
electrical connector on the vehicle wiring harness.
The power source for the CAB is through the ignitionswitch in the Run or On position.THE (CAB) IS ON
THE CCD BUS
The primary functions of the (CAB) are:
(1) Detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
(2) Control fluid modulation to the wheel brakes
while the system is in an ABS mode or the traction
control system is activated.
(3) Monitor the system for proper operation.
(4) Provide communication to the DRB Scan Tool
while in diagnostic mode.
(5) Store diagnostic information.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The CAB command coils then open and close the
valves in the HCU which modulate brake fluid pres-
sure in some or all of the hydraulic circuits. The CAB
continues to control pressure in individual hydraulic
circuits until a locking tendency is no longer present.
The ABS system is constantly monitored by the
CAB for proper operation. If the CAB detects a fault,
it will turn on the Amber ABS Warning Lamp and
disable the ABS braking system. The normal base
braking system will remain operational.
The CAB contains a self-diagnostic program which
will turn on the Amber ABS Warning Lamp when a
ABS system fault is detected. Faults are then stored
in a diagnostic program memory. There are multiple
fault messages which may be stored in the CAB and
displayed through the DRB Scan Tool. These fault
messages will remain in the CAB memory even after
the ignition has been turned off. The fault messages
can be read and or cleared from the CAB memory by
a technician using the DRB Scan Tool. The fault
occurrence and the fault code will also be automati-
Fig. 8 Front Wheel Speed Sensor
Fig. 9 Rear Wheel Speed Sensor With Disc Brakes
Fig. 10 Controller Antilock Brake (CAB)
5 - 74 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

(2) Unplug the pump motor wiring harness (Fig.
33) from the CAB.
(3) Remove the 4 bolts (Fig. 34) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 35).
INSTALL
(1) Install the CAB (Fig. 35) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 34)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 33).
(4) Install the ICU. Refer to ABS Integrated Con-
trol Unit in the Removal And Installation Section in
this group of the service manual for the Installation
procedure.
(5) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.(6) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
FRONT WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Unplug speed sensor cable connector (Fig. 36)
from vehicle wiring harness. Remove clip (Fig. 36)
attaching speed sensor cable connector to vehicle
body.
(4) Remove wheel speed sensor head to steering
knuckle attaching bolt (Fig. 37).
(5) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion,
DO NOT USE PLIERS ON SENSOR HEAD.Use
a hammer and a punch and tap edge of sensor ear,
rocking the sensor side to side until free.
(6) Remove the speed sensor cable assembly grom-
mets from the retaining bracket (Fig. 38). Remove
speed sensor cable routing clip from the frame of the
vehicle (Fig. 38).
Fig. 33 Pump Motor To CAB Wiring Harness
Fig. 34 CAB Attaching Bolts
Fig. 35 Remove/Install CAB
PLBRAKES 5 - 87
REMOVAL AND INSTALLATION (Continued)