2000 DODGE NEON ECU

CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER±SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N´m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
INSTALLATION
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding driveshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into tran-
saxle side gear as far as possible by hand.
(3) Carefully align tripod joint with transaxle side
gears. Then grasp driveshaft interconnecting shaft
and push tripod joint into transaxle side gear until
fully seated.Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.
(4) Clean all debris and moisture out of steering
knuckle (Fig. 12).
(5) Ensure that front of outer C/V joint, which fits
into steering knuckle (Fig. 13), is free of debris and
moisture before assembling into steering knuckle.(6) Slide driveshaft back into front hub. Install
steering knuckle onto the ball joint stud (Fig. 14).
NOTE: At this point, the outer joint will not seat
completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.
(7) Install aNEWsteering knuckle to ball joint
stud bolt and nut (Fig. 14). Tighten the nut and bolt
to 95 N´m (70 ft. lbs.).
Fig. 12 Steering Knuckle to C/V Joint Sealing Area
1 ± STEERING KNUCKLE
2 ± WHEEL BEARING
3 ± FRONT HUB
4 ± THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE
OF ALL DEBRIS AND MOISTURE BEFORE INSTALLING
DRIVE SHAFT IN STEERING KNUCKLE
Fig. 13 Outer C/V Joint Inspection
1 ± OUTER C/V JOINT
2 ± THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
Fig. 14 Driveshaft Installation Into Hub And Steering
Knuckle
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
3 - 6 DIFFERENTIAL AND DRIVELINEPL
REMOVAL AND INSTALLATION (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)

(16) Reconnect the steering column lower coupling
to the steering column upper coupling (Fig. 38).
Install the coupling pinch bolt an tighten the pinch
bolt nut to a torque of 28 N´m (250 in. lbs.). Install
the pinch bolt retainer pin.
(17) Remove the steering wheel holder (Fig. 37).
(18) While looking under the instrument panel at
the lower coupling, rotate the steering wheel back-
and-forth to verify that the lower coupling does not
squeak against the dash-to-coupling seal.
(19) Reconnect the battery negative terminal.
(20) Check the stop lamps to verify they are oper-
ating properly and not staying on when the pedal is
in the released position.
(21) Road test the vehicle to ensure proper opera-
tion of the brakes.
WITH MANUAL TRANSAXLE
REMOVAL
(1) Remove the instrument panel. Refer to the
INSTRUMENT PANELS AND SYSTEMS group in
this service manual for the required procedure.
(2) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 39) in a counterclock-
wise direction approximately 30 degrees.
(3) Pull the switch rearward and remove it from
its mounting bracket.
(4) Disconnect the clutch cable from the clutch
pedal spacer (Fig. 41).(5) Disconnect the wiring harness connector going
to the clutch pedal switches (Fig. 42).
(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 four nuts fastening the brake pedal
bracket to the power brake booster (Fig. 40).
(8) Remove the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
(9) Remove the brake pedal assembly.
(10) 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 onto the studs
extending down from the instrument panel support
and power brake booster (Fig. 40).
(3) 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.
Fig. 41 Clutch Cable Connection
1 ± SNAP RING
2 ± CLUTCH PEDAL SPACER
3 ± CLUTCH PEDAL
4 ± CLUTCH CABLE
Fig. 42 Wiring Harness Connector
1 ± UPSTOP SWITCH
2 ± CLUTCH PEDAL
3 ± INTERLOCK SWITCH
4 ± CONNECTOR
5 - 26 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(5) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
MASTER CYLINDER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) With the engine not running, pump the brake
pedal 4-5 strokes until the pedal feel is firm.
(2) Disconnect the negative (ground) cable from
the battery and isolate the cable.
(3) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(4) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).(5) Disconnect the two brake tubes from the mas-
ter cylinder, and two brake tubes from the propor-
tioning valves (Fig. 45). Install plugs at all of the
open brake tube outlets on the master cylinder.
(6) Clean the area around where the master cylin-
der attaches to the power brake booster using a suit-
able brake cleaner such as MopartBrake Parts
Cleaner or an equivalent.
(7) Remove the two nuts attaching the master cyl-
inder to the power brake booster.
(8) Slide the master cylinder straight out of the
power brake booster.
(9) To remove the proportioning valves, unthread
each from the master cylinder.
INSTALLATION
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) If removed, install the proportioning valves in
their master cylinder ports. The valves are identical,
so they can be installed in either master cylinder
port going to the rear brakes. Make sure the O-rings
on the proportioning valves are new.
(2) Bleed the master cylinder before installing it
on the vehicle. Refer to MASTER CYLINDER
BLEEDING in SERVICE PROCEDURES within this
section of this service manual group.
(3) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.
Fig. 44 Master Cylinder
1 ± POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 ± POWER BRAKE BOOSTER
3 ± BRAKE FLUID PRESSURE SWITCH
4 ± MASTER CYLINDER
Fig. 45 Brake Tubes At Master Cylinder
1 ± RIGHT FRONT BRAKE TUBE
2 ± LEFT FRONT BRAKE TUBE
3 ± LEFT REAR BRAKE TUBE
4 ± REAR PROPORTIONING VALVES
5 ± RIGHT REAR BRAKE TUBE
5 - 28 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Fill the reservoir with fresh clean DOT 3 brake
fluid. Refer to BRAKE FLUID LEVEL CHECKING
in the SERVICE PROCEDURES section in this sec-
tion of this service manual group.
BRAKE FLUID LEVEL SWITCH
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).
(2) Push together the retaining tabs holding the
brake fluid level switch in place in the brake fluid
reservoir (Fig. 46).
(3) Pull the brake fluid level switch out the other
side of the reservoir.
INSTALLATION
(1) Align the brake fluid level switch with its
mounting hole on the left side of the master cylinder
brake fluid reservoir. Push the switch into the fluid
reservoir until the switch retaining tabs are
expanded on the other side of the reservoir, locking it
in place (Fig. 46).
(2) Connect the brake fluid level switch wiring
connector (Fig. 44).
POWER BRAKE BOOSTER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate the cable.
(2) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(3) Remove the one nut and one bolt securing the
air cleaner box in place, then disconnect the wiring
harness connector at the air inlet sensor.
(4) Lift the air cleaner box upward enough to clear
its grommeted alignment post (Fig. 48), then move
the air cleaner box forward just enough to access the
battery tray mounting bolts.(5) Remove the 2 bolts, then the 2 nuts mounting
the battery tray to its bracket (Fig. 48). Remove the
battery tray.
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal 4-5 times while the engine is not run-
ning until a firm brake pedal is achieved.
(6) Remove the master cylinder. For the master
cylinder without ABS removal and installation proce-
dure, refer to MASTER CYLINDER in this section of
this service manual group. For the master cylinder
with ABS removal and installation procedure, refer
to MASTER CYLINDER in the ANTILOCK BRAKE
SYSTEM section of this service manual group.
(7) If the vehicle is equipped with ABS, remove the
integrated control unit (ICU). Refer to INTEGRATED
CONTROL UNIT in REMOVAL AND INSTALLA-
TION within the ANTILOCK BRAKE SYSTEM sec-
tion of this service manual group for the procedure.
(8) If the vehicle is equipped with ABS, remove the
three bolts securing the ICU mounting bracket to the
frame rail.
(9) Disconnect the vacuum hoses from the check
valve on the power brake booster (Fig. 49), but do not
remove the check valve from power brake booster.
(10) Locate the brake pedal-to-power brake booster
input rod attachment under the instrument panel.
Position a small screwdriver (Fig. 50) under the cen-
ter tang of the retaining clip. Rotate the screwdriver
enough to allow the retaining clip tang to pass over
the end of the brake pedal pin. Remove the clip.
Fig. 48 Battery Tray Mounting
1 ± BATTERY TRAY MOUNTING NUTS
2 ± BATTERY TRAY MOUNTING BOLTS
3 ± AIR CLEANER BOX POST
5 - 30 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: Use only a new brake booster input rod-
to-brake pedal retaining clip to ensure proper
retainment.
(4) Connect the power brake booster input rod-to-
brake pedal pin. Install a new retaining clip. Do not
use the old clip.
(5) Connect all previously removed vacuum hoses
to the vacuum check valve (Fig. 49).
(6) If the vehicle is equipped with ABS, install the
ICU mounting bracket on the frame rail using its
three bolts. Tighten the nuts to a torque of 23 N´m
(200 in. lbs.).
(7) If the vehicle is equipped with ABS, reinstall
the ICU. Refer to INTEGRATED CONTROL UNIT in
REMOVAL AND INSTALLATION within the
ANTILOCK BRAKE SYSTEM section of this service
manual group for the procedure.
(8) Install the master cylinder. For the master cyl-
inder without ABS removal and installation proce-
dure, refer to MASTER CYLINDER in this section of
this service manual group. For the master cylinder
with ABS removal and installation procedure, refer
to MASTER CYLINDER in the ANTILOCK BRAKE
SYSTEM section of this service manual group.
(9) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 48). Tighten the two
bolts and nuts to a torque of 34 N´m (25 ft. lbs.).
(10) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 48).
(11) Install the one nut and one bolt securing the
air cleaner box in place, then connect the wiring har-
ness connector at the air inlet sensor.
(12) Install the battery and clamp it in place.
(13) Connect the positive, then the negative
(ground) cable on the battery.
(14) Adjust the stop lamp switch as necessary.
Refer to STOP LAMP SWITCH in the ADJUST-
MENTS section of this group.
(15) Bleed the base brake system.
(16) Road test the vehicle to ensure proper opera-
tion of the brakes.
PROPORTIONING VALVE
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Using a brake pedal holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 53). This will isolate the master
cylinder from the brake hydraulic system and willnot allow the brake fluid to drain out of the master
cylinder reservoir.
(2) Disconnect the brake tube from the proportion-
ing valve requiring removal (Fig. 54).
(3) Unscrew the Proportioning valve from the mas-
ter cylinder.
Fig. 53 Brake Pedal Holder
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. 54 Proportioning Valves On Master Cylinder
1 ± RIGHT FRONT BRAKE TUBE
2 ± LEFT FRONT BRAKE TUBE
3 ± LEFT REAR BRAKE TUBE
4 ± REAR PROPORTIONING VALVES
5 ± RIGHT REAR BRAKE TUBE
5 - 32 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(3) Install the parking brake cable into the brake
support plate or the rear disc brake adapter. Be sure
the locking fingers on the cable retainer are
expanded once the cable is pushed all the way into
the support plate or brake adapter hole to ensure the
cable is securely held in place.
(4) On vehicles equipped with rear drum brakes:
²Install the parking brake cable on the parking
brake cable actuating lever (Fig. 99).
²Install the actuating spring to the brake shoe
and the brake adjustment lever (Fig. 100).
(5) On vehicles equipped with rear disc brakes:²Install the parking brake shoes actuator lever on
the parking brake cable (Fig. 102).
²Install the parking brake shoe assemblies on the
disc brake adapter (Fig. 98).
(6) Install the hub and bearing on the rear spin-
dle. Install a new hub and bearing retaining nut.
Tighten the retaining nut to a torque of 217 N´m
(160 ft. lbs.).
(7) Install the hub and bearing dust cap.
(8) On drum brake equipped vehicles, install the
rear brake drum.
(9) On vehicles equipped with rear disc brakes,
install the brake rotor, then the disc brake caliper
(Fig. 97). Install the two caliper guide pin bolts, then
tighten them to a torque of 22 N´m (192 in. lbs.).
(10) Install the rear tire and wheel assembly.
Tighten all wheel nuts to a torque of 135 N´m (100 ft.
lbs.).
(11) Lower the vehicle.
(12) Ensure that the seal grommet on the cable
that was installed from underneath is fully seated
into the floor pan.
(13) Route the parking brake cable under the car-
peting, up to parking brake cable retaining bracket
on floor pan. Install the parking brake cable through
the retaining bracket. Push the cable in until the
locking fingers on the cable retainer lock the cable
into place.
(14) Install the rear parking brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(15) Ensure that the parking brake cables are cor-
rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.
NOTE: The parking brake lever can be in any posi-
tion when releasing the automatic adjuster.
(16) 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. 93), 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.
(17) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(18) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(19) Reposition the rear carpeting into place.
(20) Install the rear seat cushion. Be sure the seat
cushion is fully installed in the retainers on the floor
pan of the vehicle.
(21) Fully apply the parking brake lever.
Fig. 103 Parking Brake Cable Removal
1 ± CABLE RETAINER
2 ± OFFSET BOX WRENCH
3 ± PARKING BRAKE CABLE
Fig. 104 Cable At Tension Strut
1 ± TENSION STRUT MOUNTING BOLTS
2 ± TENSION STRUT
3 ± SPOOL BUSHING
4 ± NUT
5 ± PARKING BRAKE CABLE
5 - 52 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(12) Pull the rear brake shoe away from anchor.
Remove the rear brake shoe and upper return spring
(Fig. 108).
(13) Remove the front brake shoe hold-down clip
(Fig. 109). Remove the front brake shoe assembly.
INSTALLATION
(1) Install the front brake shoe and secure it in
place with a hold-down clip (Fig. 109).
(2) Install the rear brake shoe and the upper shoe
return spring (Fig. 108). Pull the rear brake shoe
over the anchor block until it is properly located on
the adapter.
(3) Install the lower shoe-to-shoe return spring
(Fig. 107).
(4) Install the brake shoe adjuster assembly with
the star wheel towards the rear (Fig. 106).
(5) Install the rear brake shoe hold down clip (Fig.
105).
(6) Adjust the parking brake shoes to a diameter
to 171 mm (6.75 inch) (Fig. 110).
(7) Install the rear hub and bearing assembly on
spindle.
(8) Install a new hub and bearing assembly retain-
ing nut. Tighten the retaining nut to a torque of 217
N´m (160 ft. lbs.).
(9) Install the hub and bearing dust cap.
(10) Install the rear brake rotor.
(11) Install rear disc brake caliper.(12) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(13) Repeat the above procedure to the parking
brake shoes on the other side of the vehicle.
Fig. 108 Brake Shoe and Upper Spring
1 ± UPPER SPRING
2 ± HOLD DOWN CLIP
3 ± REAR PARKING BRAKE SHOE
Fig. 109 Front Hold Down Clip And Brake Shoe
1 ± FRONT BRAKE SHOE ASSEMBLY
2 ± HOLD DOWN CLIP
Fig. 110 Measuring Brake Shoes
1 ± REAR PARKING BRAKE SHOES
2 ± BRAKE SHOE GAUGE
5 - 54 BRAKESPL
REMOVAL AND INSTALLATION (Continued)