2000 DODGE NEON Service Repair Manual

(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 56). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Inspect and
discard these if they are worn or damaged.
(5) Remove the two brake caliper to steering
knuckle guide pin bolts (Fig. 57).
(6) Remove the disc brake caliper from the steer-
ing knuckle. The caliper is removed by first tipping
either the top (right side caliper) or bottom (left side
caliper) of the caliper away from the brake rotor,then pulling the caliper off the opposite end's caliper
slide abutment (on the knuckle) and brake rotor.
INSTALLATION
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 caliper slide
abutments with a liberal amount of MopartMulti-
purpose Lubricant, or an equivalent.
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.
(3) Install the disc brake caliper (with pads) on the
brake rotor and steering knuckle. The left side cali-
per is installed by first sliding the top of the caliper
past the top caliper slide abutment on the steering
knuckle to hook the top edge of the caliper, then
pushing the lower end of the caliper into place
against the knuckle (Fig. 58). The right side caliper
is installed by first sliding the bottom edge of the cal-
iper past the lower caliper slide abutment on the
steering knuckle to hook the lower edge of the cali-
per, then pushing the top of the caliper into place
against the steering knuckle.
Fig. 56 Brake Hose Connection
1 ± CALIPER
2 ± HOSE
3 ± BOLT
Fig. 57 Caliper Mounting
1 ± RETAINER CLIP
2 ± BRAKE ROTOR
3 ± HUB
4 ± GUIDE PIN BOLTS
5 ± DISC BRAKE CALIPER
Fig. 58 Installing Left Caliper
1 ± SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 ± BRAKING DISC
3 ± DISC BRAKE CALIPER
4 ± STEERING KNUCKLE BRAKE ABUTMENT
5 - 34 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Install the caliper guide pin bolts and tighten
them to a torque of 22 N´m (192 in. lbs.) (Fig. 57).
(5) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 56). Place one fitting
washer on each side of the hose fitting as the banjo
bolt is guided through the fitting. Install new wash-
ers if they are worn or damaged at all. Thread the
banjo bolt into the caliper and tighten it to a torque
of 48 N´m (35 ft. lbs.).
(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(7) Lower the vehicle.
(8) Remove the brake pedal holding tool.
(9) Bleed the caliper as necessary. Refer to BASE
BRAKE BLEEDING in the SERVICE PROCE-
DURES section in this service manual group.
(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
DISC BRAKE SHOES (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: Vehicles that are equipped with optional
Four-wheel-disc brake system use a different lining
material on the front disc brake shoes than vehicles
with front disc and rear drum brakes. When new
brake shoes are installed, be sure the brake shoes
for the correct type of brake system are used.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both front tire and wheel assemblies
from vehicle.
(3) Begin on one side of the vehicle.
(4) Remove the two brake caliper guide pin bolts
(Fig. 59).
(5) Remove the disc brake caliper from the steer-
ing knuckle. The caliper is removed by first tipping
either the top (right side caliper) or bottom (left side
caliper) of the caliper away from the brake rotor,
then pulling the caliper off the opposite end's caliper
slide abutment (on the knuckle) and brake rotor.
(6) Support the caliper using a wire or cord to pre-
vent the weight of caliper from damaging the brake
hose (Fig. 60). Do not let the caliper hang by the
brake hose.
Fig. 59 Caliper And Rotor Mounting
1 ± RETAINER CLIP
2 ± BRAKE ROTOR
3 ± HUB
4 ± GUIDE PIN BOLTS
5 ± DISC BRAKE CALIPER
Fig. 60 Supporting Caliper
1 ± WIRE HANGER
2 ± STEERING KNUCKLE
3 ± BRAKE DISC
4 ± DISC BRAKE CALIPER ASSEMBLY
5 ± BRAKE HYDRAULIC HOSE
PLBRAKES 5 - 35
REMOVAL AND INSTALLATION (Continued)

(7) Remove the outboard brake shoe from the cali-
per by prying the shoe retaining clip over the raised
area on the caliper. Slide the brake shoe down and
off of the caliper (Fig. 61).
(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. 62) and remove the shoe.(9) Repeat the above procedure to the front brakes
on the other side of the vehicle.
INSTALLATION
(1) Begin on one side of the vehicle.
(2) Completely retract the caliper piston back into
the bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.
(3) Remove any protective paper from the noise
suppression gasket on both the inner and outer brake
shoes (if equipped).
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing the shoe in with the
thumbs (Fig. 63). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Slide the new outboard brake shoe onto the cal-
iper (Fig. 64).
(6) Lubricate both steering knuckle caliper slide
abutments with a liberal amount of MopartMulti-
purpose Lubricant, or an equivalent.
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.
Fig. 61 Removing Outboard Brake Shoe
1 ± CALIPER ASSEMBLY
2 ± HANGER WIRE
3 ± BRAKE FLEX HOSE
4 ± OUTBOARD BRAKE PAD
5 ± HUB/BEARING ASSEMBLY
6 ± STEERING KNUCKLE
7 ± SCREWDRIVER
Fig. 62 Removing Inboard Brake Shoe
1 ± INBOARD BRAKE SHOE
2 ± HANGER WIRE
3 ± CALIPER ASSEMBLY
4 ± RETAINING CLIP
5 ± PISTON
Fig. 63 Installing Inboard Brake Shoe
1 ± PISTON
2 ± BRAKE SHOE
3 ± CALIPER ASSEMBLY
5 - 36 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(7) Install the disc brake caliper (with pads) on the
brake rotor and steering knuckle. The left side cali-
per is installed by first sliding the top of the caliper
past the top caliper slide abutment on the steering
knuckle to hook the top edge of the caliper, then
pushing the lower end of the caliper into place
against the knuckle (Fig. 65). The right side caliper
is installed by first sliding the bottom edge of the cal-
iper past the lower caliper slide abutment on the
steering knuckle to hook the lower edge of the cali-
per, then pushing the top of the caliper into place
against the steering knuckle.(8) Install the caliper guide pin bolts and tighten
them to a torque of 22 N´m (192 in. lbs.) (Fig. 59).
(9) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(10) Repeat the above procedure to the front
brakes on the other side of the vehicle.
(11) Lower the vehicle.
(12) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
(13) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
BRAKE ROTOR (FRONT)
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the front tire and wheel assembly.
(3) Remove the front disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (FRONT) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove the clips retaining the brake rotor (Fig.
59).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
INSTALLATION
(1) Install the brake rotor over the wheel mount-
ing studs and onto the hub (Fig. 59).
(2) Install the front disc brake caliper. It may be
necessary to retract the brake caliper piston back
into the caliper to fit the shoes onto the rotor, if a
new rotor is being installed. Refer to DISC BRAKE
SHOES (FRONT) in this REMOVAL AND INSTAL-
LATION section of this service manual group.
(3) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(4) Lower the vehicle.
(5) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
Fig. 64 Installing Outboard Brake Shoe
1 ± BRAKE SHOE ASSEMBLY
2 ± BRAKE CALIPER
Fig. 65 Installing Left Caliper
1 ± SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 ± BRAKING DISC
3 ± DISC BRAKE CALIPER
4 ± STEERING KNUCKLE BRAKE ABUTMENT
PLBRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)

DISC BRAKE CALIPER (REAR)
REMOVAL
(1) Using a brake pedal holding tool as shown (Fig.
66), 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 while the lines are discon-
nected.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the rear tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 67). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Inspect and
discard these if they are worn or damaged.
(5) Remove the two caliper guide pin bolts (Fig.
68).
(6) Remove the caliper assembly from the brake
adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 69).
INSTALLATION
NOTE: Step (1) below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
Fig. 66 Brake Pedal Holding Tool
1 ± CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 ± THROTTLE PEDAL
3 ± BRAKE PEDAL HOLDING TOOL
4 ± STEERING WHEEL
5 ± DRIVER'S SEAT
6 ± BRAKE PEDAL
Fig. 67 Brake Hose Mounting
1 ± BRAKE HOSE
2 ± GUIDE PIN BOLTS
3 ± CALIPER
4 ± BOLT
Fig. 68 Caliper Mounting
1 ± DISC BRAKE CALIPER
2 ± DISC BRAKE ADAPTER
3 ± GUIDE PIN BOLTS
4 ± HUB AND BEARING
5 ± BRAKE ROTOR
6 ± RETAINER CLIP
7 ± DUST CAP
8 ± NUT
5 - 38 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(1) Completely retract the caliper piston back into
piston bore of the caliper.
(2) Lubricate both adapter caliper slide abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(3) Starting with the lower end, carefully lower the
caliper and brake shoes over the brake rotor and
catch the caliper's bottom edge behind the caliper
slide abutment (Fig. 69). Rotate the top of the caliper
into mounting position on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(4) Carefully install the caliper guide pin bolts
(Fig. 68), then tighten them to a torque of 22 N´m
(192 in. lbs.).
(5) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 67). Place one fitting
washer on each side of the hose fitting as the banjo
bolt is guided through the fitting. Install new wash-
ers if they are worn or damaged at all. Thread the
banjo bolt into the caliper and tighten it to a torque
of 48 N´m (35 ft. lbs.).(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(7) Lower the vehicle.
(8) Remove the brake pedal holding tool.
(9) Bleed the caliper as necessary. Refer to BASE
BRAKE BLEEDING in the SERVICE PROCE-
DURES section in this service manual group.
(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
DISC BRAKE SHOES (REAR)
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both rear tire and wheel assemblies
from vehicle.
(3) Begin on one side of the vehicle.
(4) Remove the two caliper guide pin bolts (Fig.
70).
Fig. 69 Removing Caliper From Adapter
1 ± BRAKING DISC
2 ± CALIPER ADAPTER
3 ± CALIPER
4 ± LOWER MACHINED ADAPTER ABUTMENT
Fig. 70 Caliper And Rotor Mounting
1 ± DISC BRAKE CALIPER
2 ± DISC BRAKE ADAPTER
3 ± GUIDE PIN BOLTS
4 ± HUB AND BEARING
5 ± BRAKE ROTOR
6 ± RETAINER CLIP
7 ± DUST CAP
8 ± NUT
PLBRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)

(5) Remove the caliper assembly from the brake
adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 71).
(6) Hang the brake caliper from rear strut using
wire or cord to prevent the weight of the caliper from
damaging the brake hose (Fig. 72).
(7) Remove the outboard brake shoe from the cali-
per by prying the brake shoe retaining clip over the
raised area on the caliper. Then slide the brake shoe
down and off of the brake caliper (Fig. 73).
(8) Pull the inboard brake shoe away from caliper
piston until the retaining clip is free from the cavity
in the piston (Fig. 74).
(9) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
INSTALLATION
(1) Begin on one side of the vehicle.
(2) Completely retract the caliper piston back into
piston bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.
(3) Remove any protective paper from the noise
suppression gasket on both inner and outer brake
shoe assemblies (if equipped).
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing the shoe in with the
thumbs (Fig. 74). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Slide the outboard brake shoe onto the caliper
assembly (Fig. 73). Be sure the retaining clip is
squarely seated in the depressed areas on the caliper.
Fig. 71 Caliper Removal/Installation
1 ± BRAKING DISC
2 ± CALIPER ADAPTER
3 ± CALIPER
4 ± LOWER MACHINED ADAPTER ABUTMENT
Fig. 72 Supporting Caliper
1 ± FLEX HOSE
2 ± STRUT
3 ± WIRE HANGER
4 ± CALIPER ASSEMBLY
Fig. 73 Outboard Brake Shoe
1 ± CALIPER FINGERS
2 ± RETAINING CLIP
5 - 40 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Lubricate both adapter caliper slide abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(7) Starting with the lower end, carefully lower the
caliper and brake shoes over the brake rotor and
catch the caliper's bottom edge behind the caliper
slide abutment (Fig. 71). Rotate the top of the caliper
into mounting position on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(8) Carefully install the caliper guide pin bolts
(Fig. 70), then tighten them to a torque of 22 N´m
(192 in. lbs.).
(9) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(10) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to ensure
the vehicle has a firm brake pedal before moving the
vehicle.(13) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE ROTOR (REAR)
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear tire and wheel assembly.
(3) Remove the rear disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (REAR) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove any clips retaining the brake rotor
(Fig. 70).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
INSTALLATION
NOTE: Inspect the disc brake shoes and parking
brake shoes before brake rotor installation.
(1) Install the rear brake rotor over the wheel
mounting studs and onto the hub (Fig. 70).
(2) Install rear disc brake caliper. Refer to DISC
BRAKE SHOES (REAR) in this REMOVAL AND
INSTALLATION section of this service manual
group.
(3) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(4) Adjust the parking brake shoes as necessary.
Refer to ADJUSTMENTS in this section of this ser-
vice manual group.
(5) Lower the vehicle.
(6) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
DRUM BRAKE WHEEL CYLINDER (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
Fig. 74 Inboard Brake Shoe
1 ± RETAINING CLIP
2 ± INBOARD SHOE
PLBRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)