1999 DODGE NEON ESP

INSTALL
(1) Position power brake booster onto dash panel.
(2) Install and torque the 4 power brake vacuum
booster mounting nuts (Fig. 121) to 29 N´m (250 in.
lbs.) torque.
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake vacuum booster input rod.
(4) Connect power brake vacuum booster input rod
to brake pedal pin and install a NEW retaining clip.
Use only a new retainer clip DO NOT USE the
old clip.
(5) Connect all previously removed vacuum hoses
onto power brake vacuum booster check valve (Fig.
119).
(6) If vehicle is equipped with ABS, install HCU.
Refer to Antilock Brake System Hydraulic Control
Unit in the Removal And Installation Section of the
Antilock Brake System Section of this service manual
for the required procedure.
CAUTION: When replacing the power brake vac-
uum booster 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. If old vacuum seal came out
with master cylinder when it was removed from
power brake vacuum booster, be sure it is removed
from master cylinder before attempting to install
master cylinder into power brake vacuum booster.
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.
(7) Lubricate master cylinder push rod as indi-
cated in (Fig. 122) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(8) Install vacuum seal on master cylinder push
rod as shown with notches on vacuum seal pointing
toward master cylinder housing (Fig. 123). Then slide
vacuum seal onto master push rod until seal is
seated against master cylinder housing (Fig. 124)
before installing master cylinder on power brake vac-
uum booster.
CAUTION: If vehicle is equipped with ABS, be sure
the old vacuum seal is removed from power brake
vacuum booster before attempting to install master
cylinder and NEW vacuum seal. If vacuum seal is
not removed, refer to Master Cylinder Removal in
this section of the service manual for required vac-
uum seal removal procedure.
Fig. 122 Lubricating Master Cylinder Push Rod
Fig. 123 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 124 Vacuum Seal Positioned For Installing
Master Cylinder
5 - 46 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

PARK BRAKE LEVER ASSEMBLY
WARNING: THE AUTO ADJUSTING FEATURE OF
THIS PARKING BRAKE LEVER ASSEMBLY CON-
TAINS A CLOCK SPRING LOADED TO APPROXI-
MATELY 20 POUNDS. DO NOT RELEASE THE AUTO
ADJUSTER LOCKOUT DEVICE BEFORE INSTALL-
ING CABLES INTO THE EQUALIZER. KEEP HANDS
OUT OF AUTO ADJUSTER SECTOR AND PAWL
AREA. FAILURE TO OBSERVE CAUTION IN HAN-
DLING THIS MECHANISM COULD LEAD TO SERI-
OUS INJURY.
REMOVE
(1) Remove the screws attaching the rear of the
center console assembly to console bracket (Fig. 127)
or (Fig. 128).(2) Remove the 2 screws located in cup holders
(Fig. 129), attaching front of center console assembly
to console bracket.
(3) Raise park brake hand lever as high as it will
go to get the required clearance to remove the center
console.
(4) Remove center console assembly.
WARNING: WHEN REPAIRS TO THE PARK BRAKE
HAND LEVER ASSEMBLY OR CABLES IS
REQUIRED, THE AUTO ADJUSTER MUST BE
RELOADED AND LOCKED OUT.
(5) Lower park brake lever handle.
(6) Grasp park brake lever output cable by hand
and pull rearward (Fig. 130). Continue pulling on
cable until a 3/16 in. drill bit can be inserted into
handle and sector gear of park brake mechanism
(Fig. 130). This will lock the park brake mechanism
and take tension off park brake cables.
Fig. 126 Non-ABS Proportioning Valve Locations On
Master Cylinder
Fig. 127 Center Console Rear Attaching Screws W/O
Arm Rest
Fig. 128 Center Console Rear Attaching Screws
With Arm Rest
Fig. 129 Attaching Screws At Front Of Center
Console
5 - 48 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

of the park brake lever. The park brake lever output
cable (Fig. 135) should never be attempted to be
repaired in any manner. Follow the require proce-
dures under park brake lever removal and replace-
ment when servicing a park brake lever output cable.
PARK BRAKE CABLES
NOTE: Note: Remove only one rear park brake
cable from rear brakes at a time. Failure to do so
will result in high efforts required to connect park
brake cables to equalizer or park brake lever at rear
wheel brakes.
For installation of the rear park brake cables fol-
low the procedure as listed below.
REMOVE
(1) Remove screws attaching rear of center console
assembly to floor pan of vehicle (Fig. 136) or (Fig.
137).(2) Remove the 2 screws located in cup holders
(Fig. 138) attaching front of center console to console
bracket.
(3) Raise park brake lever as high as it will go for
the clearance required to remove the center console.
(4) Remove center console assembly from vehicle.
WARNING: WHEN REPAIRS TO THE PARK BRAKE
HAND LEVER ASSEMBLY OR CABLES IS
REQUIRED, THE AUTO ADJUSTER MUST BE
RELOADED AND LOCKED OUT.
(5) Lower park brake lever handle.
(6) Grasp park lever output cable by hand and pull
rearward (Fig. 139). Continue pulling on cable until a
3/16 in. drill bit can be inserted into handle and sec-
tor gear of park brake mechanism (Fig. 139). This
will lock the park brake mechanism and take tension
off park brake cables.
Fig. 134 Removing Lockout Pin From Park Brake
Lever Assembly
Fig. 135 Brake Lever Assembly And Output Cable
Fig. 136 Center Console W/O Arm Rest Rear
Attaching Screws
Fig. 137 Center Console With Arm Rest Rear
Attaching Screws
5 - 50 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(13) Remove rear wheel and tire assembly.
(14) On vehicles equipped with rear drum brakes,
remove brake drum (Fig. 143) 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. 144) from hub/
bearing assembly.
(15) Remove the dust dust cap (Fig. 145) from the
rear hub/bearing.
(16) Remove the retaining nut (Fig. 146) for the
hub/bearing from the spindle.
(17) Remove thehub/bearing (Fig. 147) from the
rear spindle.
(18)On vehicles equipped with rear drum
brakes,remove park brake cable from park brakeactuating lever (Fig. 148). Then remove the actuating
spring (Fig. 149) between brake shoe adjustment
lever and brake shoe assembly.
Fig. 143 Brake Drum Removal
Fig. 144 Rear Brake Rotor
Fig. 145 Dust Cap Removal
Fig. 146 Hub/Bearing Retaining Nut
Fig. 147 Hub/Bearing Removal From Spindle (Drum
Brakes Shown)
5 - 52 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Install park brake cable into floor pan of vehi-
cle making sure sealing grommet is installed in floor
pan as far as possible to insure proper seal.
(2) Install park brake cable into brake support
plate or rear disc brake adapter. Be sure locking tabs
on cable retainer are expanded to ensure park brake
cable is securely held in support plate or adapter.
(3) Install park brake cable routing bracket (Fig.
154) on frame rail. Install and securely tighten rout-
ing bracket attaching bolt.
(4)On vehicles equipped with rear drum
brakes,install park brake cable on park brake cable
actuating lever (Fig. 148). Then install actuating
spring between brake shoe assembly and brake
adjustment lever (Fig. 149).
(5)On vehicles equipped with rear disc
brakes,install park brake shoes actuator lever (Fig.
151) on park brake cable. Then install park brake
shoe assemblies on disc brake adapter (Fig. 150).
(6) Install the hub/bearing assembly on the rear
spindle. Then installA NEWrear hub/bearing
assembly retaining nut. Torque hub/bearing assembly
retaining nut to 217 N´m (160 ft. lbs.).
(7) Install hub/bearing assembly dust cap, using a
soft faced hammer.
(8) On drum brake equipped vehicles, install rear
brake drum on hub/bearing assembly. On vehicles
equipped with rear disc brakes, install rotor on hub/
bearing assembly.
(9) On disc brake equipped vehicles install disc
brake caliper on disc brake adapter. Install the 2 cal-
iper guide pin bolts (Fig. 156) and torque to 22 N´m
(192 in. lbs.). Refer To Rear Disc Brake Service in
this group of the service manual for the required cal-
iper installation procedure.
(10) Install rear wheel and tire assembly on vehi-
cle. Tighten all wheel stud nuts in criss cross pattern
Fig. 153 Park Brake Cable Removal From Disc
Brake Adapter
Fig. 154 Park Brake Cable Routing Bracket
Fig. 155 Park Brake Cable Seal At Floor PanFig. 156 Rear Caliper Guide Pin Bolts
5 - 54 BRAKESPL

(11) Remove front brake shoe hold-down clip (Fig.
164). Then remove front brake shoe assembly.
INSTALL
(1) Install front brake shoe and hold down clip
(Fig. 164).
(2) Install rear brake shoe and the upper brake
shoe to shoe return spring (Fig. 163).
(3) Pull rear brake shoe over anchor block until
properly located on adapter.(4) Install the lower shoe to shoe return spring
(Fig. 162).
(5) Install brake shoe adjuster assembly with star
wheel rearward (Fig. 161).
(6) Install rear brake shoe hold down clip (Fig.
160).
(7) Adjust brake shoes to a diameter to 171 mm
(6.75 inch).
(8) Install rear hub and bearing assembly on spin-
dle.
Fig. 160 Rear Brake Shoe Hold-Down Clip
Fig. 161 Park Brake Shoe Adjuster Assembly
Fig. 162 Brake Shoe Lower Return Spring
Fig. 163 Brake Shoe and Upper Spring
5 - 56 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(5) Install new master cylinder housing to brake
fluid reservoir sealing grommets (Fig. 166) in master
cylinder housing.
(6) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
grommets. Seat reservoir into grommets using a
rocking motion while firmly pressing down on fluid
reservoir.
(7) Be sure reservoir is positioned properly.
(8) Make sure bottom of reservoir touches top of
grommet.
BRAKE FLUID LEVEL SWITCH
The master cylinder or brake fluid reservoir does
not have to be removed from vehicle for replacement
of the brake fluid level sensor.
(1) Remove wiring harness connector from brake
fluid reservoir level sensor (Fig. 167).
(2) Compress retaining tabs (Fig. 168) on end of
brake fluid level switch.(3) While compressing retaining tabs, grasp oppo-
site end of brake fluid level switch and pull it out of
master cylinder brake fluid reservoir (Fig. 169).
(4) Correctly align the replacement level switch
with its mounting hole in the brake fluid reservoir.
Push switch into fluid reservoir until retaining tabs
are fully expanded on opposite side of fluid reservoir
(Fig. 168).
(5) Install the wiring harness connector onto the
brake fluid level switch.
FRONT AND REAR DISC BRAKE CALIPER
CLEANING AND INSPECTION
Check for brake fluid leaks in and around dust
boot area and inboard brake pad, and for any rup-
tures, brittleness or damage to the piston dust boot.
If the dust boot is damaged, or a fluid leak is visible,
disassemble caliper assembly and install a new pis-
ton seal and dust boot, and piston if scored. Refer to
Fig. 166 Removing Fluid Reservoir From Master
Cylinder
Fig. 167 Master Cylinder Fluid Level Sensor
Fig. 168 Brake Fluid Level Switch Retaining Tabs
Fig. 169 Removing/Installing Fluid Reservoir Level
Switch
5 - 58 BRAKESPL
DISASSEMBLY AND ASSEMBLY (Continued)

sleeve (Fig. 176). Be sure other end of bushing did
not come out of seal grove in sleeve.
(8) When the sleeve is seated properly into the
bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve
groove.CALIPER DISASSEMBLY
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE EVER BE USED TO REMOVE A PISTON
FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
(1) Remove caliper from brake rotor (See Brake
Shoe Removal). Hang assembly on a wire hook away
Fig. 173 Installing Caliper Guide Pin Bushing
Fig. 174 Bushing Correctly Installed In Caliper
Fig. 175 Installing Sleeve In Bushing
Fig. 176 Correctly Installed Caliper Sleeve And
Bushing
5 - 60 BRAKESPL
DISASSEMBLY AND ASSEMBLY (Continued)