2000 DODGE NEON brakes

BRAKE ROTOR
The brake shoe linings contact the brake rotor.
Each front brake rotor is vented to help cool it during
and after brake applications. It is mounted on the
studs of the front wheel bearing hub.
DRUM BRAKES (REAR)
Rear drum brakes are standard equipment on this
vehicle. The rear drum brakes consist of the major
components listed in the figure (Fig. 7). Other com-
ponents related to the brake shoes themselves can be
seen in the next figure (Fig. 8).
The rear wheel drum brakes are a two-shoe, inter-
nal-expanding type with an automatic adjuster screw
(Fig. 8). The automatic adjuster screw is actuated
each time the brakes are applied. The automatic
adjuster screw is located directly below the rear
brake wheel cylinder.
Fig. 5 Front Disc Brake Caliper
1 ± CALIPER GUIDE PIN BOLT
2 ± SLEEVE
3 ± BUSHING
4 ± CALIPER
5 ± PISTON SEAL
6 ± PISTON
7 ± DUST SEAL
8 ± WEAR INDICATOR
9 ± ANTI-RATTLE CLIP10 ± BRAKE SHOE
11 ± BRAKE SHOE
12 ± ANTI-RATTLE CLIP
13 ± BUSHING
14 ± SLEEVE
15 ± CALIPER GUIDE PIN BOLT
16 ± CAP
17 ± BLEEDER SCREW
Fig. 6 Piston Seal Function
1 ± PISTON
2 ± CYLINDER BORE
3 ± PISTON SEAL BRAKE PRESSURE OFF
4 ± CALIPER HOUSING
5 ± DUST BOOT
6 ± PISTON SEAL BRAKE PRESSURE ON
PLBRAKES 5 - 5
DESCRIPTION AND OPERATION (Continued)

DISC BRAKES (REAR)
Rear disc brakes are optional equipment on some
models of this vehicle (Fig. 9). The rear disc brakes
are similar to the front disc brakes; however, there
are several distinctive features that require different
service procedures. The rear disc brakes consist of
the following components:
²Brake caliper - single-piston, floating type
²Brake caliper adapter
²Brake shoe and linings
²Brake rotor - drum-in-hat type
All vehicles equipped with rear disc brakes have a
small duo-servo drum brake mounted to the caliper
adapter. This is part of the parking brake system.
The drum brake shoes expand out against a braking
surface (hat section) on the inside area of the disc
brake rotor.
BRAKE CALIPER
Vehicles are equipped with a caliper assembly that
has a 34 mm (1.43 in.) piston and uses a solid non-
vented rotor.
The caliper assembly for all applications floats on
rubber bushings using internal metal sleeves that
are attached to the adapter using threaded guide pin
bolts.
BRAKE CALIPER ADAPTER
The brake caliper adapter and rotor shield are
mounted to the rear suspension knuckles of vehicle.
Fig. 7 Rear Drum Brakes
1 ± DUST CAP
2 ± NUT
3 ± DRUM
4 ± HUB AND BEARING
5 ± WHEEL CYLINDER
6 ± SEAL
7 ± SUPPORT PLATE
8 ± BRAKE SHOES
9 ± RETAINER CLIP
Fig. 8 Drum Brake Shoes (Left Side Shown)
1 ± WHEEL CYLINDER
2 ± AUTOMATIC ADJUSTER SCREW ASSEMBLY
3 ± RETURN SPRING
4 ± HOLD DOWN CLIP
5 ± HOLD DOWN CLIP
6 ± AUTOMATIC ADJUSTER LEVER AND SPRING
7 ± PARK BRAKE LEVER
8 ± PARK BRAKE CABLE
9 ± FRONT BRAKE SHOE
10 ± BRAKE SHOE TO ANCHOR SPRING
11 ± BRAKE ANCHOR PLATE
12 ± REAR BRAKE SHOE
Fig. 9 Rear Disc Brakes
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 - 6 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

The adapter is used to mount the brake caliper to the
vehicle (Fig. 9). The adapter has two machined abut-
ments, which are used to position and align the cal-
iper and brake pads for movement inboard and
outboard. The adapter also mounts the parking brake
shoes and actuating cables to the vehicle.
PARKING BRAKES
The parking brakes (Fig. 4) consist of the following
components:
²Hand-operated park brake lever - automatic-ad-
justing
²Parking brake cables
²Actuation levers and struts
²Duo-servo parking brake assembly (rear disc
only)
PARKING BRAKE LEVER
All vehicles are equipped with a center-mounted,
hand-operated parking brake lever mounted between
the front seats (Fig. 10). This lever is an automatic-
adjusting type that continuously applies minimal
tension to the parking brake cables to keep them in
adjustment at all times. Due to this feature, the
parking brake cable system does not require adjust-
ment. Proper parking brake system adjustment is
obtained by proper drum brake or drum-in-hat brake
shoe adjustment. When service is needed, the lever
auto-adjust mechanism must be reloaded and locked
out before service can be performed.
The parking brake lever has a short output cable
with an equalizer bracket attached to it that connects
to the parking brake cables (Fig. 10). The output
cable can only be serviced as part of the parking
brake lever.PARKING BRAKE CABLES
There is an individual parking brake cable for each
rear wheel that joins a parking cable equalizer,
attached to the parking brake lever, to the rear park-
ing brakes. The parking brake cables are made of
flexible steel cable. Both drum rear brakes and disc
rear brakes use the same parking brake cable config-
uration, but the cables are different.
PARKING BRAKES
On vehicles equipped with rear drum brakes, the
rear wheel service brakes also act as the vehicle's
parking brakes. The rear drum brake shoes, when
acting as parking brakes, are mechanically operated
using an internal actuating lever and strut connected
to the flexible steel parking brake cable.
The parking brakes on vehicles equipped with rear
disc brakes consist of a small duo-servo brake assem-
bly mounted to the disc brake caliper adapter (Fig.
11). The hat (center) section of the rear brake rotor
serves as the braking surface (drum) for the parking
brakes (Fig. 12). This parking brake application uses
the same operating cable configuration as the drum
brake equipped vehicles, but different cables.
Fig. 10 Parking Brake Lever
1 ± PARKING BRAKE LEVER
2 ± PARKING BRAKE WARNING LAMP SWITCH
3 ± OUTPUT CABLEFig. 11 Parking Brake Assembly With Rear Disc
Brakes
1 ± DISC BRAKE ADAPTER
2 ± PARKING BRAKE BRAKE SHOES
3 ± HUB/BEARING ASSEMBLY
4 ± BRAKING DISC STONE SHIELD
5 ± PARKING BRAKE ACTUATING STRUT
PLBRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)

RED BRAKE WARNING LAMP
The red BRAKE warning lamp is located in the
instrument panel cluster and illuminates when a low
brake fluid condition occurs or when the parking
brake lever is applied with the ignition key in the
ON position. In addition, the red BRAKE warning
lamp illuminates when the ignition switch is moved
from the OFF to the ON or CRANK position. This is
done to check the bulb's operation.
Problems with this system will generally be of the
type where the warning lamp fails to turn on when it
should, or remains on when it should not.
The red BRAKE warning lamp LED is supplied
with current anytime the ignition switch is ON. The
bulb is illuminated by completing the ground circuit
using any of the following components:
²the brake fluid level switch located in the mas-
ter cylinder reservoir
²the parking brake switch mounted on the park-
ing brake lever (Fig. 10)
²the ignition switch when the ignition switch is
first moved to the ON or CRANK position
²the mechanical instrument cluster (MIC) (with
ABS)
²the ABS electronic brake distribution (EBD)
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder assembly (Fig.
1). The purpose of the switch is to provide the driver
with an early warning that the brake fluid level inthe master cylinder reservoir has dropped below an
acceptable level.
As the fluid drops below the minimum level, the
fluid level switch closes and grounds the red BRAKE
warning lamp circuit. This turns on the red BRAKE
warning lamp. At this time, the master cylinder fluid
reservoir must be checked and filled to the full mark
with DOT 3 brake fluid. An abnormal loss of brake
fluid in the master cylinder fluid reservoir could be
caused by a leak in the hydraulic system. The entire
brake hydraulic system should be checked for evi-
dence of a leak.
The red BRAKE warning lamp can be turned on by
the MIC in the case where the ABS is experiencing a
problem where the amber ABS warning lamp needs
to be illuminated and cannot. The MIC will then illu-
minate the red BRAKE warning lamp.
BRAKE LAMP SWITCH
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 13). It con-
trols operation of the vehicle's stop lamps. Also, if the
vehicle is equipped with speed control, the brake
lamp switch will deactivate the speed control when
the brake pedal is depressed.
When the brake pedal is depressed, the brake lamp
switch contacts are closed, completing the circuit to
the stop lamps, thus illuminating the stop lamps and
the center-high-mounted stop lamp (CHMSL).
Fig. 12 Drum-In-Hat Brake Rotor
1 ± REAR BRAKING DISK ROTOR
2 ± HAT SECTION OF REAR BRAKING DISC (PARKING BRAKE
BRAKING SURFACE)
Fig. 13 Brake Lamp Switch
1 ± SWITCH
2 ± CLIP
3 ± BRAKE PEDAL
4 ± CONNECTOR
5 - 8 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING LAMP,
BRAKE NOISE and OTHER BRAKE CONDITIONS.
RED BRAKE WARNING LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp switch
on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp
goes out, replace switch.
5. Mechanical instrument cluster (MIC)
problem.5. Refer to Chassis Diagnostic Procedures
manual.
6. ABS EBD malfunction. 6. Refer to ABS section and Chassis
Diagnostic Procedures manual.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.2. Lubricate brake caliper slides.
DISC BRAKE RATTLE OR
CLUNK1. Broken or missing anti-rattle spring
clips on shoes.1. Replace brake shoes.
2. Caliper guide pins loose. 2. Tighten guide pins.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.1. Lubricate shoe contact areas on brake
shoe support plates.
2. Wheel cylinder out of alignment. 2. Loosen wheel cylinder mounting bolts,
realign wheel cylinder with brake shoes and
tighten mounting bolts.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN1. Lack of lubricant on brake shoe
support plate where shoes ride and at
the anchor.1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING1. ABS wheel speed sensor or tone
wheel.1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL).1. Foreign object interference with
brakes.1. Inspect brakes and remove foreign object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
PLBRAKES 5 - 9

OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or rotors
as necessary.
BRAKES DRAG (FRONT OR
ALL)1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
BRAKES DRAG (REAR
ONLY)1. Parking brake cables binding or
froze up.1. Check cable routing. Replace cables as
necessary.
2. Parking brake cable return spring
not returning shoes.2. Replace cables as necessary.
3. Service brakes not adjusted properly
(rear drum brakes only).3. Follow the procedure listed in the
adjustment section.
4. Obstruction inside the center
console preventing full return of the
parking brake cables.4. Remove console and remove
obstruction.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.2. Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL
EFFORT1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist. 2. Refer to power brake booster in the
diagnosis and testing section.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL
TRAVEL (PEDAL GOES TO
FLOOR - CAN'T SKID
WHEELS)1. Power brake booster runout
(vacuum assist).1. Check booster vacuum hose and
engine tune for adequate vacuum supply.
Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP DURING
HARD BRAKING)1. One of the two hydraulic circuits to
the front brakes is malfunctioning.1. Inspect system for leaks. Check master
cylinder for internal malfunction.
5 - 10 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
PEDAL PULSATES/SURGES
DURING BRAKING1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or rotors
as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).2. Check booster vacuum hose and
engine tune for adequate vacuum supply.
Refer to power brake booster in the
diagnosis and testing section.
PREMATURE REAR WHEEL
LOCKUP1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles only).2. Test proportioning valves folowing
procedure listed in diagnosis and testing
section. Replace valves as necessary.
3. ABS EBD not functioning. 3. Refer to the ABS section and Chassis
Diagnostic Procedures manual.
4. Improper power brake booster
assist.4. Refer to power brake booster in the
diagnosis and testing section.
STOP LAMPS STAY ON 1. Brake lamp switch out of
adjustment.1. Adjust brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.4. Replace power brake booster.
VEHICLE PULLS TO RIGHT
OR LEFT ON BRAKING1. Frozen brake caliper piston. 1. Replace frozen piston or caliper. Bleed
brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL1. Rear brakes out of adjustment. 1. Adjust rear drum brake shoes, or rear
parking brake shoes on vehicles with rear
disc brakes.
POWER BRAKE BOOSTER
BASIC TEST
(1) With engine off, depress and release the brake
pedal several times to purge all vacuum from the
power brake booster.
(2) Depress and hold the pedal with light effort (15
to 25 lbs. pressure), then start the engine.
The pedal should fall slightly, then hold. Less effort
should be needed to apply the pedal at this time. If
the pedal fell as indicated, perform the VACUUM
LEAK TEST listed after the BASIC TEST. If thepedal did not fall, continue on with this BASIC
TEST.
(3) Disconnect the vacuum hose on the side of the
vacuum check valve that leads to the speed control,
then connect a vacuum gauge to the open vacuum
port on the valve.
(4) Start the engine.
(5) When the engine is at warm operating temper-
ature, allow it to idle and check the vacuum at the
gauge.
PLBRAKES 5 - 11
DIAGNOSIS AND TESTING (Continued)

If the vacuum supply is 12 inches Hg (40.5 kPa) or
more, the power brake booster is defective and must
be replaced. If the vacuum supply is below 12 inches,
continue on with this BASIC TEST.
(6) Shut off the engine.
(7) Connect the vacuum gauge to the vacuum ref-
erence port on the engine intake manifold.
(8)
Start the engine and observe the vacuum gauge.
If the vacuum is still low, check the engine tune
and repair as necessary. If the vacuum is above 12
inches, the hose or check to the booster has a restric-
tion or leak.
Once an adequate vacuum supply is obtained,
repeat the BASIC TEST.
VACUUM LEAK TEST
(1) Disconnect the vacuum hose on the side of the
power brake booster vacuum check valve that leads
to the speed control, then connect a vacuum gauge to
the open vacuum port on the valve.
(2) Remove the remaining hose on the vacuum
check valve that is not the vacuum supply hose com-
ing from the intake manifold. Cap off the open port
on the check valve.
(3) Start the engine.
(4) Allow the engine to warm up to normal operat-
ing temperature and engine idle.
(5) Using vacuum line pliers, close off the vacuum
supply hose near the booster and observe the vacuum
gauge.
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa)
in one minute, repeat the above steps to confirm the
reading. The vacuum loss should be less than 1.0
inch Hg in one minute time span. If the loss is more
than 1.0 inch Hg, replace the power brake booster. If
it is not, continue on with this test.
(6) Remove the pliers from the hose temporarily.
(7) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.
Do not move the pedal once the pressure is applied
or the test results may vary.
(8) Have an assistant reattach the pliers to the
vacuum supply hose.
(9) Allow 5 seconds for stabilization, then observe
the vacuum gauge.
If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective.
DRUM BRAKE AUTOMATIC ADJUSTER
To properly test the drum brake automatic
adjuster, the aide of a helper inside the vehicle to
apply the brakes will be necessary.(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the access plug from the rear adjust-
ment slot in each brake support plate.
(3) Insert a thin screwdriver in the adjustment
slot and push back the adjustment lever. With the
lever in this position, back the star wheel adjustment
off approximately 10 notches. This will eliminate the
possibility that the brake is at full adjustment, and
can be adjusted no further.
(4)
Remove the screwdriver from the adjustment slot.
(5) Watch the star wheel through the adjustment
slot, while a helper applies the brake pedal. As the
brake shoes apply, the adjustment lever should move
downward, turning the star wheel. A definite rotation
of the adjuster star wheel can be observed if the
automatic adjuster is working properly.
If the star wheel does not move as indicated, the
brake drum needs to be removed and further inspec-
tion of the rear brakes is necessary.
(6) If the star wheel is operating properly, readjust
the brakes. Refer to ADJUSTMENTS in this section
of this service manual group.
(7) Reinstall the adjustment slot access plug.
(8) Lower the vehicle.
BRAKE ROTOR
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock-back. This increases
guide pin sleeve wear due to the tendency of the cal-
iper to follow the rotor wobble.
When diagnosing a brake noise or pulsation, the
machined disc braking surface should be checked and
inspected.
BRAKING SURFACE INSPECTION
Light braking surface scoring and wear is accept-
able. If heavy scoring or warping is evident, the rotor
must be refaced or replaced. Refer to SERVICE PRO-
CEDURES in this section of this group for informa-
tion on brake rotor machining.
Excessive wear and scoring of the rotor can cause
improper lining contact on the rotor's braking sur-
face. If the ridges on the rotor are not removed before
new brake shoes are installed, improper wear of the
shoes will result.
If a vehicle has not been driven for a period of
time, the rotor's braking surface will rust in the
areas not covered by the brake shoes at that time.
Once the vehicle is driven, noise and chatter from
the disc brakes can result when the brakes are
applied.
5 - 12 BRAKESPL
DIAGNOSIS AND TESTING (Continued)