2000 DODGE NEON Service Repair Manual

CAUTION: Before removing the master cylinder
cap, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder res-
ervoir.
CAUTION: Use only MoparTbrake fluid or an equiv-
alent from a fresh, tightly sealed container. Brake
fluid must conform to DOT 3 specifications.
Do not pump the brake pedal at any time while
having a bleeder screw open during the bleeding pro-
cess. This will only increase the amount of air in the
system and make additional bleeding necessary.
Do not allow the master cylinder reservoir to run
out of brake fluid while bleeding the system. An
empty reservoir will allow additional air into the
brake system. Check the fluid level frequently and
add fluid as needed.
The following wheel circuit 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
MANUAL BLEEDING
NOTE: To bleed the brakes manually, the aid of a
helper will be required.
(1) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 26).
(2) Have a helper pump the brake pedal three or
four times and hold it in the down position.
(3) With the pedal in the down position, open the
bleeder screw at least 1 full turn.
(4) Once the brake pedal has dropped, close the
bleeder screw. After the bleeder screw is closed,
release the brake pedal.
(5) Repeat the above steps until all trapped air is
removed from that wheel circuit (usually four or five
times).
(6) Bleed the remaining wheel circuits in the same
manner until all air is removed from the brake sys-
tem. Monitor the fluid level in the master cylinder
reservoir to make sure it does not go dry.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
PRESSURE BLEEDING
NOTE: Follow pressure bleeder manufacturer's
instructions for use of pressure bleeding equip-
ment.
Following the same wheel circuit sequence as pre-
scribed for manual bleeding.
(1) Attach Adapter, Special Tool 6921, to the mas-
ter cylinder reservoir (Fig. 27).
Fig. 26 Proper Method for Purging Air From Brake
System (Typical)
1 ± CLEAR HOSE
2 ± BRAKE CALIPER
3 ± BLEEDER SCREW
4 ± CLEAN BRAKE FLUID
Fig. 27 Special Tool 6921
1 ± MASTER CYLINDER
5 - 18 BRAKESPL
SERVICE PROCEDURES (Continued)

(2) Attach Bleeder Tank, Special Tool C-3496-B, or
an equivalent, to the adapter on the master cylinder.
(3) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 26).
(4) Open the bleeder screw at least one full turn or
more to obtain a steady stream of brake fluid.
(5) After approximately 4±8 ounces of fluid have
been bled through the brake circuit and an air-free
flow is maintained in the clear plastic hose and jar,
close the bleeder screw.
(6) Repeat this procedure at all the remaining
bleeder screws.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
MASTER CYLINDER BLEEDING
(1) Clamp the master cylinder in a vise.
(2) Attach four Master Cylinder Bleed Tubes, Spe-
cial Tool 8358-1, to the four ports of the master cyl-
inder and tighten each in place (Fig. 28). The bleed
tubes for the ports pertaining to the rear brakes are
made to attach to the proportioning valves screwed
into the master cylinder. Position the other end of
the tubes into the master cylinder reservoir so their
outlets are below the surface of the brake fluid in the
reservoir when filled.
(3) Fill the brake fluid reservoir with Mopart
brake fluid, or an equivalent conforming to DOT 3
specifications.
(4) Using a wooden dowel as a pushrod (Fig. 28),
press the pistons inward slowly applying brake pres-
sure, then release the pressure, allowing the pistons
to return to the released position. Repeat this several
times until all air bubbles are expelled out of the
tubes and master cylinder bore.
(5) Remove the bleed tubes from the master cylin-
der and plug the outlet ports.
(6) Install the fill cap on the reservoir.
(7) Remove the master cylinder from the vise.
NOTE: It is not necessary to bleed the entire
hydraulic system after replacing just the master cyl-
inder unless the brake system has been open to air
for an excessive amount of time or air is present in
the lines. Only the master cylinder must be bled
and filled.
BRAKE TUBE REPAIR
Use only double wall 4.75 mm (3/16 in.) steel tub-
ing with Nygal coating for hydraulic brake tube
replacement. Nygal is nylon coated galvanized steel
tubing.
Care must be taken when repairing brake tubing
to avoid kinking the tube. Use the proper bending
and flaring tools. Do not route the tubes against
sharp edges, moving components, or into hot areas.
All tubes should be attached with the recommended
retaining clips.
PREPARING THE BRAKE TUBE FOR FLARING
(1) Use Tubing Cutter, Special Tool C-3478-A, or
an equivalent to cut off the damaged flare or tubing
(Fig. 29).
(2) Make the ends of the tubing to be repaired
square (Fig. 30) to ensure better seating of the flared
end tubing.
(3) Ream out any burrs or rough edges showing on
the inside of the tubing to be flared (Fig. 30).
(4) Strip back enough of the nylon coating at the
end of the length of tubing that will flared so it will
not be in the flare itself. At least 5 mm should be
removed.
NOTE: Place a tube nut on the tubing before flaring
it. It cannot be done after the tube is flared.
Fig. 28 Bleeding Master Cylinder
1 ± WOODEN DOWEL
2 ± MASTER CYLINDER
PLBRAKES 5 - 19
SERVICE PROCEDURES (Continued)

DOUBLE INVERTED TUBING FLARES
After preparing the tubing using the procedure in
PREPARING THE BRAKE TUBE FOR FLARING,
make a double inverted tubing flare using the follow-
ing procedure (Fig. 31).
CAUTION: When using brake tubing with Nygal
coating, always use flare nuts designed for this
coating. They have a larger hole in the center to
accommodate the coating on the tube.
(1) Install the replacement flare nut on the tube so
the threads are facing the flare yet to be made (Fig.
32).
(2) Open the Flaring Tool, Special Tool C-4047 (or
an equivalent), separating the tools vertical posts.
(3) Place the tubing in the jawed hole between the
two vertical posts.
(4) Slowly bring the vertical posts together captur-
ing the tube between the halves. Leave enough tub-
ing sticking through the top of the vertical posts to
allow for flaring. Apply only enough pressure to hold
the tube in place.
Fig. 29 Cutting And Flaring Of Brake Fluid Tubing
Fig. 30 Brake Fluid Tube Preparation For Flaring
1 ± BE SURE ALL BURRS ARE REMOVED FROM INSIDE OF
TUBING
2 ± BE SURE END OF TUBING IS SQUARE BEFORE FLARING
TUBE
3 ± HYDRAULIC BRAKE LINE TUBING
Fig. 31 Double Inverted Brake Line Tubing Flare
1 ± DOUBLE INVERTED-STYLE FLARE
Fig. 32 Double Wall Inverted Flare Connection
1 ± INVERTED FLARE TUBE NUT
2 ± SEAT
3 ± INVERTED DOUBLE FLARE
4 ± TUBE
5 - 20 BRAKESPL
SERVICE PROCEDURES (Continued)

(5) Place the gauge (From A) over the end of the
brake tube. Adjust the tube height in the tool's jaws
until the end of the tube contacts the recessed notch
in the gauge that matches the tubing size. Squeeze
the handles of the flaring tool, locking the tubing in
place. Remove the gauge.
(6) Place the 3/16 inch plug gauge (A) down into
the end of the tube. Tighten the flaring handle, push-
ing the gauge into the tube until the gauge contacts
the vertical posts of the tool.
(7) Release the flaring handle and remove the plug
gauge from the partially flared tube.
(8) Tighten the flaring handle down once more
until the tools flaring tip has firmly seated the tube
to the vertical posts, thus completing the flare.
CAUTION: When inspecting the flare, make sure no
tubing nygal coating has been involved in the flare.
(9) Remove the flared tube from the flaring tool
and inspect the flare to make sure it is uniform.
BRAKE ROTOR MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servicing of the rotor requires extreme care to
maintain the rotor 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 brake
pedal pulsation, the rotor should be refaced using a
hub-mounted on-car brake lathe (Fig. 33), or
replaced.The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle's hub and bearing.
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 34).
Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
SPECIFICATIONS AND LIMITS
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.
Fig. 33 On-Car Brake Lathe
1 ± ON-CAR BRAKE LATHE
Fig. 34 Minimum Brake Rotor Thickness Markings
(Typical)
1 ± ROTOR MINIMUM THICKNESS MARKING
2 ± ROTOR
PLBRAKES 5 - 21
SERVICE PROCEDURES (Continued)

BRAKE ROTOR LIMITS
Braking Rotor Rotor ThicknessMinimum
Rotor
ThicknessRotor
Thickness
VariationRotor Run
Out*Rotor Micro
Finish
Front Rotor21.87±22.13 mm
0.861-0.871 in.20.4 mm
0.803 in.0.013 mm
0.0005 in.0.08 mm
0.003 in.15-80 RMS
Rear Rotor8.75±9.25 mm
0.344 -0.364 in.7.25 mm
0.285 in.0.013 mm
0.0005 in.0.08 mm
0.003 in.15-80 RMS
* TIR Total Indicator Reading (Measured On Vehicle)
BRAKE DRUM MACHINING
If a brake drum is deeply scored or warped, it can
be machined on a brake lathe equipped to machine
brake drums. Follow the manufacturers instructions
on the machining procedure.
Measure the brake drum diameter before machin-
ing. If machining the drum will cause the drum to
exceed maximum allowable diameter, do not machine
the brake drum. It needs to be replaced.
CAUTION: Do not machine the brake drum if it will
cause the drum to exceed maximum allowable
diameter.
All brake drums are marked with the maximum
allowable brake drum diameter (Fig. 35).
When machining, make sure the final finish feed
cut is fine in order to avoid a screw effect on the
brake shoes when the brakes are applied. This finalfeed cut specification varies from lathe manufacturer
to lathe manufacturer.
PARKING BRAKE AUTOMATIC ADJUSTER LOCK
OUT
WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARKING
BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY.
ADJUSTER LOADING AND LOCKING OUT
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 36). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
Fig. 35 Brake Drum Maximum Diameter
Identification
1 ± HUB/BEARING ASSEMBLY
2 ± WHEEL MOUNTING STUDS
3 ± BRAKE DRUM MAXIMUM DIAMETER MARKING
4 ± REAR BRAKE DRUM
5 - 22 BRAKESPL
SERVICE PROCEDURES (Continued)

ADJUSTER UNLOADING (UNLOCKING)
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster locking pin or pin punch.
(1) Be sure the rear parking brake cables are both
properly installed in the equalizer.
(2) Keeping your hands clear of the automatic
adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 36), then quickly
remove it from the parking brake lever mechanism.
This will allow the park brake lever mechanism to
automatically adjust the parking brake cables.
(3) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(4) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(5) Fully apply the parking brake lever.(6) Install the center console and its mounting
screws.
(7) Remove the blocks from the tire and wheels.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE SHOE LININGS ARE MADE FROM ASBES-
TOS-FREE MATERIALS, SOME AFTERMARKET
BRAKE SHOE LININGS MAY CONTAIN ASBESTOS.
THIS SHOULD BE TAKEN INTO ACCOUNT WHEN
SERVICING A VEHICLE'S BRAKE SYSTEM. IT IS
POSSIBLE THAT AFTERMARKET BRAKE SHOES
MAY HAVE BEEN INSTALLED ON THE VEHICLE.
ALWAYS WEAR A RESPIRATOR WHEN CLEANING
BRAKE COMPONENTS; ASBESTOS CAN CAUSE
SERIOUS BODILY HARM SUCH AS ASBESTOSIS
AND CANCER. NEVER CLEAN BRAKE COMPO-
NENTS BY USING COMPRESSED 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 CREATE BRAKE LINING DUST
BY SANDING THE BRAKE LININGS WHEN SERVIC-
ING A VEHICLE. DISPOSE OF ALL DUST AND DIRT
SUSPECTED OF CONTAINING ASBESTOS FIBERS.
USE ONLY SEALED AIRTIGHT BAGS OR CONTAIN-
ERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL PROTECTION AGENCY
(EPA), FOR HANDLING AND DISPOSING OF PROD-
UCTS CONTAINING ASBESTOS.
CAUTION: Use only MoparTbrake fluid or an equiv-
alent 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.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash it off immediately with water.
CAUTION: During service procedures, grease or
any other foreign material must be kept off the cal-
iper assembly, surfaces of the brake rotor and
external surfaces of the hub. Avoid deformation,
scratching or nicking of the brake rotor and brake
shoe linings.
Fig. 36 Pin Punch Installed
1 ± PARKING BRAKE LEVER
2 ± PIN PUNCH
3 ± OUTPUT CABLE
PLBRAKES 5 - 23
SERVICE PROCEDURES (Continued)

BRAKE PEDAL
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
WITH AUTOMATIC TRANSAXLE
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Place the steering wheel and tires in the
STRAIGHT-AHEAD position. Using a steering wheel
holder, lock the steering wheel in place to keep it
from rotating (Fig. 37). This keeps the clockspring in
the proper orientation.
(3) Remove the steering column coupling retainer
pin, back off the pinch bolt nut, and remove the
steering column coupling pinch bolt (Fig. 38) (the
pinch bolt nut is caged to the coupling and is not
removable). Separate the upper and lower steering
column couplings.
(4) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 39) in a counterclock-
wise direction approximately 30 degrees.
(5) Pull the switch rearward and remove it from
its mounting bracket.
(6) Remove the clip securing the power brake
booster input rod to the brake pedal (Fig. 39).
Remove the input rod from the brake pedal.
(7) Remove the two upper nuts fastening the brake
pedal bracket to the power brake booster (Fig. 40).(8) Carefully pry the tie bar running between the
two upper booster mounting studs from its plastic
retaining fasteners.
(9) Remove the two remaining nuts fastening the
brake pedal bracket to the power brake booster (Fig.
40).
Fig. 37 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 38 Steering Column Couplings
1 ± STEERING COLUMN UPPER COUPLING
2 ± PINCH BOLT
3 ± STEERING COLUMN LOWER COUPLING
4 ± BRAKE PEDAL
5 ± NUT
6 ± RETAINER PIN
Fig. 39 Brake Lamp Switch
1 ± SWITCH
2 ± CLIP
3 ± BRAKE PEDAL
4 ± CONNECTOR
5 - 24 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(10) If the vehicle is equipped with antilock
brakes, carefully push the power brake booster for-
ward until the booster contacts the ABS ICU mount-
ing bracket.
(11) If the vehicle does not have antilock brakes,
carefully push the power brake booster forward one
to two inches being careful not to stretch the brake
lines from the master cylinder to the brakes.
(12) Remove the two nuts fastening the brake
pedal bracket to the instrument panel support (Fig.
40).
(13) Carefully remove the brake pedal assembly by
pulling the pedal bracket back toward the instru-
ment panel, releasing the bracket from the booster
studs. Next, tip the bracket down past the input rod,
guiding the rod through the gap left by the missing
brace removed in Step (8). Remove the brake pedal
assembly out from under the instrument panel.
(14) The pedal can be removed from it's bracket by
grinding off the peened end of the shaft, removing
the shaft, pedal and bushings. A service parts pack-
age is available to replace these items.
INSTALLATION
(1) If the pedal has been removed from it's
bracket, install the pedal, bushings and bolt-in-shaft
on the bracket using the available service parts pack-
age.
(2) Install the brake pedal assembly by tipping the
pedal bracket and guiding the power brake booster
mounting portion up past the booster input rod.
Guide the top of the bracket onto the studs protrud-
ing from the instrument panel support (Fig. 40), then
guide the booster mounting portion onto the power
brake booster mounting studs.(3) Push the power brake booster back into mount-
ing position from under the hood.
(4) Install the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
Install the nuts all the way, but do not tighten them
at this time.
(5) Install the two lower power brake booster
mounting nuts, but do not tighten them at this time.
(6) Place the tie bar running between the two
upper booster mounting studs onto the studs with
the long flat side facing upward and the curved side
downward.
(7) Install the two upper power brake booster
mounting nuts on their studs.
(8) Tighten all four nuts fastening the brake pedal
bracket to the power brake booster to a torque of 34
N´m (300 in. lbs.).
(9) Tighten the two nuts fastening the brake pedal
bracket to the instrument panel support to a torque
of 34 N´m (300 in. lbs.).
(10) Install the power brake booster input rod on
the pin mounted on the side of the brake pedal.
Install a new retaining clip on the end of the pin
(Fig. 39). Do not reuse the old clip.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it's fully extended posi-
tion.
(11) Hold the brake lamp switch firmly in one
hand. Then using the other hand, pull outward on
the plunger of the brake lamp switch until it has
ratcheted out to its fully extended position.
(12) Mount the brake lamp switch into the bracket
using the following procedure:
²Depress the brake pedal as far down as possible.
²Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
²When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30É to lock
the switch into place.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(13) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(14) Install the dash-to-lower coupling seal in
place over the lower coupling's plastic collar and
dash cover.
(15) Verify the front tires are still in the
STRAIGHT-AHEAD position.
Fig. 40 Brake Pedal Mounting
1 ± CLUTCH CABLE
2 ± BOOSTER MOUNTING NUTS
3 ± UPPER MOUNTING NUTS
PLBRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)