2000 DODGE NEON torque

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) 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)

(7) 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. 65). 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.(8) Install the caliper guide pin bolts and tighten
them to a torque of 22 N´m (192 in. lbs.) (Fig. 59).
(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 front
brakes on the other side of the vehicle.
(11) Lower the vehicle.
(12) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
(13) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake pads.
BRAKE ROTOR (FRONT)
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the front tire and wheel assembly.
(3) Remove the front disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (FRONT) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove the clips retaining the brake rotor (Fig.
59).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
INSTALLATION
(1) Install the brake rotor over the wheel mount-
ing studs and onto the hub (Fig. 59).
(2) Install the front disc brake caliper. It may be
necessary to retract the brake caliper piston back
into the caliper to fit the shoes onto the rotor, if a
new rotor is being installed. Refer to DISC BRAKE
SHOES (FRONT) in this REMOVAL AND INSTAL-
LATION 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) Lower the vehicle.
(5) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
Fig. 64 Installing Outboard Brake Shoe
1 ± BRAKE SHOE ASSEMBLY
2 ± BRAKE CALIPER
Fig. 65 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
PLBRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)

(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)

(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)

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. 75). 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) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the rear tire and wheel assembly.
(4) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 76).
(5) Remove the rear brake drum.
(6) Remove the rear brake shoes from the brake
support plate. Refer to DRUM BRAKE SHOES in
this REMOVAL AND INSTALLATION section.
NOTE: If the brake shoes are wet with grease or
brake fluid, replace them.
(7) Remove the brake wheel cylinder attaching
bolts (Fig. 76).
(8) Remove the brake wheel cylinder from the
brake support plate (Fig. 77).
INSTALLATION
(1) Install a new O-ring at the mating surface of
the wheel cylinder-to-brake support plate (Fig. 77).NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake assembly.
(2) Install the wheel cylinder onto brake support
plate (Fig. 77). Tighten the attaching bolts to a
torque of 13 N´m (115 in. lbs.).
(3) Hand start the rear brake flex hose tube fitting
to wheel cylinder. Tighten the tube nut to a torque of
17 N´m (145 in. lbs.).
(4) Install the rear brake shoes on the brake sup-
port plate. Replace them as necessary.
(5) Install the rear brake drum onto the rear hub.
Fig. 75 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. 76 Brake Flex Hose At Wheel Cylinder
1 ± BRAKE SUPPORT PLATE
2 ± WHEEL CYLINDER ATTACHING BOLTS
3 ± REAR BRAKE FLEX HOSE TUBE
4 ± WHEEL CYLINDER ASSEMBLY
Fig. 77 Remove/Install Wheel Cylinder
1 ± WHEEL CYLINDER
2 ± SUPPORT PLATE
3 ± O-RING
5 - 42 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(7) Adjust the rear brakes. Refer to ADJUST-
MENTS in this section of this service manual group.
(8) Lower the vehicle.
(9) Remove the brake pedal holder.
(10) Bleed the wheel cylinder as necessary. Refer
to BASE BRAKE BLEEDING in the SERVICE PRO-
CEDURES section in this service manual group.
(11) Road test the vehicle to make sure the brakes
operate correctly.
DRUM BRAKE SHOES (REAR)
NOTE: Before proceeding with this removal and
installation procedure, review the SERVICE WARN-
INGS 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 both rear tire and wheel assemblies
from the vehicle.
(3) Begin on one side of the vehicle.
(4) Remove the brake drum retaining clips (if
equipped) (Fig. 78).(5) Remove the brake drum (Fig. 78).
(6) Remove the automatic adjustment lever-to-
brake shoe spring (Fig. 79).
(7) Remove the automatic adjustment lever (Fig.
80) from the brake shoe.
(8) Remove the hold down clips and pins attaching
the leading and trailing brake shoes to the brake
support plate (Fig. 81).
(9) Remove the lower brake shoe-to-anchor plate
return spring (Fig. 82).
(10) Remove the parking brake lever pin-to-brake
shoe retaining clip (Fig. 83).
Fig. 78 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. 79 Automatic Adjustment Lever Spring
1 ± ADJUSTMENT LEVER
2 ± ADJUSTMENT LEVER TO BRAKE SHOE SPRING
3 ± HUB/BEARING
4 ± LEADING BRAKE SHOE
5 ± AUTOMATIC ADJUSTER SCREW
Fig. 80 Automatic Adjustment Lever
1 ± AUTOMATIC ADJUSTMENT LEVER
2 ± FRONT BRAKE SHOE ASSEMBLY
PLBRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

(6) Install the pin on the parking brake lever into
hole in rear brake shoe assembly (Fig. 86).
(7) Install both brake shoe-to-brake support plate
hold down pins and clips (Fig. 81).
(8) Install the lower brake shoe-to-anchor plate
return spring (Fig. 82).
(9) Install the automatic adjustment lever on the
leading brake shoe (Fig. 80).(10) Install the automatic adjustment lever-to-
brake shoe spring (Fig. 79).
(11) Adjust the brake shoes out until the drum
lightly drags on the shoes when it is installed. Do not
over-adjust the brakes.
(12) Install the brake drum (Fig. 78).
(13) Repeat the above procedure to the rear brakes
on the other side of the vehicle.
(14) Install the tire and wheel assemblies. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(15) Adjust the rear brake shoes. Refer to
ADJUSTMENTS in this section of this service man-
ual group.
(16) Lower the vehicle.
(17) Road test vehicle stopping in both the forward
and reverse directions. The automatic adjuster will
continue to adjust the brakes during the road test of
the vehicle.
BRAKE DRUM (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 from
the vehicle.
(3) Remove the brake drum retaining clips (if
equipped) (Fig. 87).
Fig. 85 Shoe Contact Areas on Support Plate
Fig. 86 Parking Brake Lever Pin Retaining Clip
Installation
1 ± BRAKE SHOE ASSEMBLY
2 ± RETAINING CLIP
3 ± SCREWDRIVER
4 ± PARK BRAKE LEVER
5 ± PARK BRAKE LEVER PIN
Fig. 87 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
PLBRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)