2000 DODGE NEON brake rotor

(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)

INSTALLATION
(1) Place the parking brake lever on the mounting
studs on the vehicle floor. Install and tighten the two
mounting nuts to a torque of 28 N´m (250 in. lbs.)
(Fig. 95).
(2) Connect the wiring harness electrical connector
on the parking brake warning lamp switch (Fig. 95).
(3) Install both rear park brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(4) 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 only be in the
released position when releasing the automatic
adjuster.
(5) 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.
(6) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(7) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(8) Fully apply the parking brake lever.
(9) Install the center console and its mounting
screws.
(10) Remove the blocks from the tires and wheels.
PARKING BRAKE CABLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
The procedure below applies to either of the two
rear parking brake cables.
REMOVAL
(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. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the rear seat cushion from the vehicle.
(8) Fold the rear carpeting forward to expose the
parking brake cables at the end of the rear floor.
(9) Install the box end of a 1/2 inch wrench over
the parking brake cable retainer (Fig. 96). Push the
wrench onto the retainer until the retainer fingers
are collapsed. From under the carpeting, grasp the
parking brake cable housing and pull cable straight
out of the bracket attached to the floor.
(10) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(11) Remove the rear tire and wheel assembly
from the vehicle.
(12) On vehicles equipped with rear drum brakes,
remove the brake drum. Refer to BRAKE DRUM in
this section of this service manual group.
(13) On vehicles equipped with rear disc brakes:
²Remove the disc brake caliper guide pin bolts,
then the caliper from disc brake adapter (Fig. 97).
²Hang the caliper out of the way using a wire
hanger or cord.
²Remove the brake rotor from the rear hub and
bearing.
(14) Remove the dust cap from the rear hub and
bearing.
Fig. 95 Parking Brake Lever
1 ± MOUNTING NUTS
2 ± PARKING BRAKE LEVER
3 ± PARKING BRAKE WARNING LAMP SWITCH CONNECTOR
PLBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

(15) Remove the hub and bearing retaining nut
from the knuckle spindle, then remove the hub and
bearing (Fig. 97).
(16) On vehicles equipped with rear disc brakes,
remove the upper return spring, both shoe hold-down
clips, then spread the rear parking brake shoes apart
at the top enough to clear the shoe anchor and
remove the parking brake shoes as an assembly from
the disc brake adapter (Fig. 98).
(17) To remove the rear parking brake cable from
the brake support plate on vehicles equipped with
rear drum brakes:
²Remove the parking brake cable from the park-
ing brake actuating lever (Fig. 99).
²Remove the actuating spring between the brake
shoe adjustment lever and the brake shoe (Fig. 100).
²Remove the parking brake cable from the rear
brake support plate. The parking brake cable can be
removed from brake support plate using a 1/2 inch
box wrench to compress the locking fingers on the
parking brake cable retainer (Fig. 101).
(18) To remove the rear parking brake cable from
the disc brake adapter on vehicles equipped with
rear disc brakes:
²Remove the parking brake actuating lever from
the parking brake cable (Fig. 102).
Fig. 96 Compressing Cable Retainer
1 ± CARPET ROLLED FORWARD
2 ± WRENCH
3 ± RIGHT REAR CABLE
4 ± REAR PARKING BRAKE CABLES
5 ± LEFT REAR CABLE
Fig. 97 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
Fig. 98 Parking Brake Shoes
1 ± UPPER RETURN SPRING
2 ± SHOE HOLD DOWN CLIPS
3 ± ADJUSTER
4 ± LOWER REAR SPRING
5 ± DISC BRAKE ADAPTER
5 - 50 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)

(22) Install the center console and its mounting
screws.
(23) Remove the blocks from the tires and wheels.
PARKING BRAKE SHOES (REAR DISC BRAKE)
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) 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 rear brake rotor.
(5) Remove the dust cap from the rear hub and
bearing.
(6) Remove the rear hub and bearing assembly
retaining nut and washer.
(7) Remove the rear hub and bearing assembly
from the rear spindle.
(8) Remove the rear brake shoe assembly hold-
down clip (Fig. 105).(9) Turn the brake shoe adjuster wheel until the
adjuster is at shortest length.
(10) Remove the adjuster assembly from the park-
ing brake shoe assemblies (Fig. 106).
(11) Remove the lower shoe-to-shoe spring (Fig.
107).
Fig. 105 Rear Brake Shoe Hold-Down Clip
1 ± HOLD DOWN CLIP
Fig. 106 Parking Brake Shoe Adjuster Assembly
1 ± ADJUSTER
Fig. 107 Brake Shoe Lower Return Spring
1 ± LOWER SPRING
PLBRAKES 5 - 53
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)