2000 DODGE NEON tow

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)

(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)

(4) Position the master cylinder on the studs of the
power brake booster, aligning the push rod of the
power brake booster with master cylinder piston
push rod. Carefully push the master cylinder onto
the studs until it contacts the face of the booster.
(5) Install the two master cylinder mounting nuts
and tighten each to a torque of 28 N´m (250 in. lbs.).
(6) Connect the four brake tubes to the master cyl-
inder and proportioning valve ports (Fig. 45). Tighten
all tube nuts to a torque of 17 N´m (145 in. lbs.).
(7) Connect the brake fluid level switch wiring
connector.
(8) Install the battery and clamp it in place.
(9) Connect the positive, then the negative
(ground) cable on the battery.
(10) Fill the master cylinder to the proper level.
(11) Road test the vehicle to ensure proper opera-
tion of the brakes.
BRAKE FLUID RESERVOIR
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: The master cylinder does not need to be
removed from the power brake booster for removal
and installation of the brake fluid reservoir.
REMOVAL
(1) Clean the master cylinder housing and brake
fluid reservoir exterior surfaces.
(2) Remove the brake fluid reservoir cap. Using a
clean syringe or siphoning tool, empty as much brake
fluid as possible from the reservoir.
(3) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 44).
(4) Remove the two plastic pins holding the reser-
voir to the master cylinder (Fig. 46).
(5) Lift the reservoir from the master cylinder
casting.
(6) Remove the grommets sealing the reservoir to
the master cylinder housing (Fig. 47).
INSTALLATION
(1) Install new sealing grommets in the master
cylinder housing (Fig. 47).
(2) Lubricate the sealing grommets with fresh
clean DOT 3 brake fluid. Place the reservoir in posi-
tion over the grommets making sure the filler hole is
towards the front of the vehicle. Seat the reservoir
into the grommets. While holding the reservoir firmly
against the grommets, install the two plastic pins
previously removed through their mounting holes
until they protrude out the other side of the master
cylinder reservoir (Fig. 46).
(3) Connect the brake fluid level switch wiring
connector (Fig. 44).
Fig. 46 Master Cylinder Reservoir
1 ± BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 ± RESERVOIR RETAINING PINS
3 ± SEAL
Fig. 47 Sealing Grommets
1 ± MASTER CYLINDER
2 ± GROMMETS
3 ± SEAL
PLBRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)

CAUTION: Discard the used retaining clip, it is not
to be reused. Replace the clip with a new one on
reassembly.
(11) Remove the four nuts attaching the power
brake booster to the instrument panel (Fig. 51). The
nuts are accessible from under the instrument panel
in the area of the brake pedal bracket.
(12) Slide the power brake booster forward until
mounting studs clear the instrument panel. Turn the
booster sideways (Fig. 52), then remove it from the
vehicle.
INSTALLATION
(1) Turn the power brake booster sideways (Fig.
52), then install it into the engine compartment down
past the heater hoses and the strut tower. Rotate the
booster so its four mounting studs and input rod are
pointed straight toward the instrument panel. Slide
the input rod and studs through the instrument
panel and into mounting position.
(2) Under the instrument panel, install the four
power brake booster mounting nuts (Fig. 51). Tighten
the nuts to a torque of 34 N´m (300 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake booster input rod.
Fig. 49 Vacuum Check Valve
1 ± VACUUM CHECK VALVE
Fig. 50 Retaining Clip
1 ± BRAKE PEDAL
2 ± INPUT ROD
3 ± SCREWDRIVER
4 ± RETAINING CLIP
5 ± BRAKE PEDAL PIN
Fig. 51 Power Brake Booster Mounting
1 ± POWER BRAKE BOOSTER MOUNTING NUTS
2 ± BRAKE PEDAL
Fig. 52 Booster Removal/Installation
1 ± POWER BRAKE BOOSTER
PLBRAKES 5 - 31
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)

(14) Adjust the parking brake shoes as necessary.
Refer to ADJUSTMENTS in this section of this ser-
vice manual group.
(15) Lower the vehicle.
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER (FRONT AND REAR)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING AND INSPECTION
in this section of this service manual group.
CALIPER GUIDE PIN BUSHING
REMOVAL
(1) With one hand, push the guide pin bushing
sleeve towards the back of the caliper, and at the
same time, pull the sleeve out the back of the caliper
and bushing (Fig. 111).
(2) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss
(Fig. 112).INSTALLATION
(1) Fold the guide pin bushing in half lengthwise
at the solid middle section (Fig. 113).
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
Fig. 111 Removing Sleeve From Bushing
1 ± CALIPER
2 ± SLEEVE
3 ± BUSHING
Fig. 112 Removing Bushing From Caliper
1 ± CALIPER
2 ± BUSHING
Fig. 113 Folded Caliper Guide Pin Bushing
1 ± CALIPER GUIDE PIN BUSHING
PLBRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)

(14) Refer to DISASSEMBLY AND ASSEMBLY in
this section of this group for the procedure on sepa-
rating and reattaching the CAB to the HCU.
INSTALLATION
(1) Install the ICU onto its mounting bracket.
(2) Install the 3 bolts attaching the ICU to the
mounting bracket (Fig. 17). Tighten the 3 mounting
bolts to a torque of 11 N´m (97 in. lbs.)
(3) Install the four brake tubes going to the brakes
into their respective outlet ports on the ICU HCU
(Fig. 15). Using a crow foot on a torque wrench,
tighten the four brake tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: When installing the brake tubes from the
master cylinder on the HCU, the brake tube with the
small tube nut is to be installed in the forward-most
port on the HCU with the small end going toward
the master cylinder secondary port.
(4) Install the primary and secondary brake tubes
from the master cylinder onto the HCU (Fig. 15). Do
not completely tighten the primary and secondary
tubes at this time.
(5) Connect the primary and secondary brake
tubes to the master cylinder ports (Fig. 15).
(6) Using a crow foot on a torque wrench, tighten
the primary and secondary brake tube nuts at both
the master cylinder and HCU to a torque of 17 N´m
(145 in. lbs.).
CAUTION: Before installing the 25-way connector
in the CAB, be sure the seal is properly installed in
the connector.(7) Install the 25-way connector into the socket of
the CAB as follows:
²Position the 25-way connector in the socket of
the CAB and carefully push it down as far as possi-
ble (Fig. 16).
²When the connector is fully seated into the CAB
socket, push the connector lock inward. This pulls
the connector into the socket of the CAB and locks it
in the installed position.
(8) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 14). Tighten the two
bolts and nuts to a torque of 15 N´m (135 in. lbs.).
(9) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 14).
(10) 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.
(11) Install the battery and clamp it in place.
Tighten the hold-down clamp bolt to a torque of 12
N´m (105 in. lbs.).
(12) Connect the positive, then the negative
(ground) cable on the battery.
(13) Bleed the base and the ABS hydraulic sys-
tems. Refer to ANTILOCK BRAKE SYSTEM
BLEEDING in this section of this service manual
group.
(14) Fill the master cylinder to the proper fill
level.
(15) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
WHEEL SPEED SENSOR (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Disconnect the wheel speed sensor cable con-
nector from the wiring harness on the inside of the
frame rail above the front suspension crossmember
(Fig. 18). The connector has a locking tab which that
must be pulled back before the connector release
tang can be depressed, releasing the connection.
(3) Remove the speed sensor cable grommet from
the retaining bracket attached to the brake hose on
the outside of the frame rail.
(4) Remove the bolt mounting the wheel speed sen-
sor head to the steering knuckle (Fig. 19).
Fig. 17 ICU Mounting Bolts
1 ± ICU
2 ± ICU MOUNTING BOLTS
PLBRAKES 5 - 81
REMOVAL AND INSTALLATION (Continued)

SERVICE DIAGNOSIS±CLUTCH INTERLOCK/UPSTOP SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE STARTER
WON'T CRANK
WHEN CLUTCH
PEDAL IS
PRESSED TO THE
FLOORClutch interlock switch does not have
continuity when plunger is depressed 1.25
mm (1.30 in.)Defective switch or open wiring circuit.
Replace switch if necessary.
Interlock switch plunger is not depressed
when clutch pedal is pushed to the floorFloor mat interferes with clutch pedal
movement or clutch pedal bracket is bent.
Problem is related to other components in
the starting circuit.Check other components in the starting
circuit. Refer to Battery/Starting/Charging
System in Group 8.
SPEED CONTROL
DOES NOT
TERMINATE WHEN
CLUTCH PEDAL IS
DEPRESSED BY AT
LEAST 33 mm (1.30
in.)Upstop switch circuit is closed when clutch
pedal is depressed, or harness is shorted.Refer to Upstop Switch Electrical Test in
this group. Repair wiring or replace switch
assembly as necessary.
Other speed control system failure. Refer to Group 8H, Speed Control for
further diagnosis and testing procedures.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Disconnect both battery cables.
(2) Remove battery clamp and remove battery
from vehicle.
(3) Remove battery tray from mount bracket.
(4) Remove bellhousing cap (Fig. 7).
(5) Disconnect clutch cable from transaxle housing
and clutch release lever as shown in (Fig. 7).
(6) Disconnect the clutch cable from the clutch
pedal spacer (Fig. 8).
NOTE: Use care when handling clutch cable
assembly. Improper handling can cause adjuster
mechanism to come apart, making re-installation
difficult.
(7) Carefully guide cable through pedal assembly
bore and remove from vehicle.
INSTALLATION
(1) Insert the clutch pedal end of the cable into
position and connect the cable to the clutch pedal
spacer as shown in (Fig. 8).
(2) Verify adjuster mechanism function as follows:
(a) With slight pressure, pull the clutch release
lever end of the cable to draw the cable taut.(b) Push the clutch cable housing toward the
dash panel (With less than 25 lbs. of effort, the
cable housing should move 30-50mm.). If the cable
Fig. 7 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
PLCLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)