2000 DODGE NEON steering

Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced. If cracks or burned spots are evi-
dent, the rotor must be replaced.
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if it is worn
below minimum thickness or if machining the rotor
will cause its thickness to fall below specifications.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Minimum thickness specifications are cast on the
rotor's unmachined surface (Fig. 14). Limits can also
be found in the table at the end of this brake rotor
information.
ROTOR THICKNESS VARIATION
Thickness variation in a rotor's braking surface
can result in pedal pulsation, chatter and surge. This
can also be caused by excessive runout in the rotor or
the hub.
Rotor thickness variation measurements should be
made in conjunction with measuring runout. Mea-
sure thickness of the brake rotor at 12 equal points
around the rotor braking surface with a micrometer
at a radius approximately 25 mm (1 inch) from edge
of rotor (Fig. 15). If thickness measurements vary by
more than 0.013 mm (0.0005 inch), the rotor should
refaced or replaced. Refer to SERVICE PROCE-
DURES in this section of this group for information
on brake rotor machining.
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout ofthe rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP- 1910
on steering arm. The dial indicator plunger should
contact braking surface of rotor approximately one
inch from edge of rotor (Fig. 16). Check lateral runout
on both sides of the rotor, marking the low and high
spots on both. Runout limits can be found in the table
at the end of this brake rotor information.
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing the
rotor from the hub, place a chalk mark across both
the rotor and the one wheel stud closest to where the
high runout measurement was taken. This way, the
original mounting spot of the rotor on the hub is
indexed (Fig. 17).
Remove the rotor from the hub.
NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an
accurate indicator reading.
Mount Dial Indicator, Special Tool C-3339, and
Mounting Adaptor, Special Tool SP-1910, to the steer-
ing knuckle. Position the indicator stem so it contacts
the hub face near the outer diameter. Care must be
taken to position stem outside of the stud circle, but
inside of the chamfer on the hub rim (Fig. 18).
Fig. 14 Minimum Brake Rotor Thickness Markings
(Typical)
1 ± ROTOR MINIMUM THICKNESS MARKING
2 ± ROTOR
Fig. 15 Checking Rotor For Thickness
1 ± CALIPER
PLBRAKES 5 - 13
DIAGNOSIS AND TESTING (Continued)

The in-line proportioning valves used on this vehi-
cle require special pressure fittings to test the pro-
portioning valves for proper proportioning valve
function. The pressure fittings are installed before
and after the proportioning valve being tested to ver-
ify proportioning valve is maintaining the required
hydraulic pressure to the rear wheel brake which it
controls.
The testing of proportioning valves for this vehicle,
if equipped with ABS, can be found in the
ANTILOCK BRAKE SYSTEM section.
PROPORTIONING VALVE TEST
The test procedure is the same for either rear pro-
portioning valve. After road testing the vehicle to
determine which wheel skids first, follow the proce-
dure below for testing the suspect proportioning
valve.
(1) Using a brake pedal holding tool as shown (Fig.
22), 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.
(2) Use the figure shown to determine which pro-
portioning valve needs to be tested (Fig. 21).
(3) Remove the hydraulic brake tube from the pro-
portioning valve controlling the rear wheel of the
vehicle that has premature wheel skid.
(4) Remove the proportioning valve from its outlet
port on the master cylinder.CAUTION: Be sure the pressure test fittings being
installed into master cylinder and proportioning
valve, have the correct thread sizes needed.
(5) Install the Brake Pressure Adapters, Special
Tool 8644 and 6805-3 onto the proportioning valve
(Fig. 23).
(6) Install the proportioning valve (with tools) back
into the outlet port on the master cylinder.
(7) Attach a Pressure Gauge, Special Tool
C-4007-A, to each pressure adapter (Fig. 24).
(8) Remove the brake pedal holding tool. Bleed any
air out of the pressure gauge hoses at the pressure
gauge.
(9) With the aid of a helper, apply pressure to the
brake pedal until the reading on proportioning valve
inlet gauge is at the target inlet pressure shown in
the BRAKE PROPORTIONING VALVE APPLICA-
TIONS AND PRESSURE SPECIFICATIONS table
Fig. 22 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. 23 Tools On Valve
1 ± PROPORTIONING VALVE
Fig. 24 Pressure Gauge Set
1 ± SPECIAL TOOL C-4007±A
5 - 16 BRAKESPL
DIAGNOSIS AND TESTING (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)

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)

INSTALLATION
(1) Lubricate the O-ring on the proportioning
valve. Make sure the O-ring on the proportioning
valve is new.
(2) Install the proportioning valve in its master
cylinder port. Tighten the proportioning valve to a
torque of 40 N´m (30 ft. lbs.).
(3) Connect the brake tube to the proportioning
valve (Fig. 54). Tighten the tube nut to a torque of 17
N´m (145 in. lbs.).
(4) Remove the brake pedal holder (Fig. 53).
(5) Bleed the affected brake line. See BASE
BRAKE BLEEDING in the SERVICE PROCE-
DURES section in this service manual group.
(6) Road test the vehicle to ensure proper opera-
tion of the brakes.
BRAKES TUBES AND HOSES
NOTE: Brake hoses for each brake are unique and
are not interchangeable.
Always use Mopartreplacement brake hoses to
ensure quality, correct length and superior fatigue
life. Care should be taken to make sure that the tube
and hose mating surfaces are clean and free from
nicks and burrs.
Use new copper seal washers on all connections
using banjo bolts and tighten all the fittings to their
specified torques.
Follow the procedures in the next three paragraphs
to reduce the potential for twisting the brake hose
during installation.
The flexible front hydraulic brake hose should
always be installed on the vehicle by first attaching
the banjo fitting to the disc brake caliper. Attach the
hose to the brake tubing before attaching it to the
front frame rail. Tighten all brake line fittings to the
specified torque.
On vehicles equipped with rear drum brakes,
loosely install the rear brake hose to the wheel cylin-
der first, then bolt the intermediate routing bracket
to the strut. Next, loosely install the hose to the steel
tube coming from the master cylinder. Attach the
hose bracket to the body. Finally, tighten the tube
nuts at each end of the brake hose.
On vehicles equipped with rear disc brakes, attach
the brake hose banjo fitting to the caliper first, then
loosely install the hose to the steel tube coming from
the master cylinder. Next, attach the brake hose
bracket to the body. Finally, tighten the tube nut at
the each of the end of the brake hose connecting to
the steel tube coming from the master cylinder.Only double wall 4.75 mm (3/16 in.) steel brake
line tubing with Nygal coating should be used for
replacement along with its special tube nuts. Care
must be taken when replacing brake tubing; to be
sure, use the proper bending and flaring tools, and
procedures to avoid kinking. Do not route the tubes
against sharp edges, moving components, or into hot
areas. All tubes should be properly attached with the
recommended retaining clips.
DISC BRAKE CALIPER (FRONT)
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 holding tool as shown (Fig.
55), 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 when the lines are opened.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the front tire and wheel assembly.
Fig. 55 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
PLBRAKES 5 - 33
REMOVAL AND INSTALLATION (Continued)

(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)