Dodge Neon / Neon SRT-4. Manual — part 44
(5) Remove the heater core coolant supply tube
support bracket bolts (Fig. 111).
(6) Remove the (2) coolant reservoir retaining bolts
from the dash panel. Disconnect the coolant overflow
hose from the thermostat housing and remove the
coolant reservoir from the dash panel.
(7) Working
from
underneath
the
instrument
panel, disconnect the brake pedal push rod. Remove
the retaining clip from the end of the brake pedal
mounted stud, then slide the push rod straight off
the pin.
(8) If equipped, disconnect the clutch pedal push
rod. Depress the plastic retention clip on the end of
the clutch pedal mounted stud, while sliding the
push rod straight off the stud.
(9) Rotate the clutch master cylinder to line up the
square shaped retaining boss with the square shaped
opening in the brake pedal support bracket.
(10) Remove the (4) brake booster retaining nuts.
(11) Working from inside the engine compartment,
remove the (2) clutch fluid reservoir retaining bolts
from the dash panel.
(12) Remove the clutch master cylinder from the
dash panel by pulling it straight out. Position the
reservoir and line assembly out of the way.
(13) Remove the brake booster from the dash
panel by pulling it straight out, then rotate the
booster and slide it between the engine and the dash
panel towards the battery tray. Slide the booster
under the heater core coolant supply hoses and out of
the engine bay.
INSTALLATION
INSTALLATION - LHD
(1) Turn the power brake booster sideways (Fig.
109), 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. 108).
Tighten the nuts to a torque of 34 N·m (25 ft. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake booster input rod.
CAUTION: Use only a new brake booster input rod-
to-brake pedal retaining clip to ensure proper
retainment.
CAUTION: Install a new brake lamp switch anytime
the old switch is removed, the brake booster or
pedals have been changed or removed.
Fig. 110 RHD MASTER CYLINDER
1 - POWER BRAKE VACUUM BOOSTER
2 - BRAKE FLUID LEVEL SENSOR
3 - MASTER CYLINDER
4 - BRAKE FLUID RESERVOIR
Fig. 111 HEATER CORE COOLANT SUPPLY HOSES
1 - COOLANT LINE SUPPORT BRACKET BOLTS
2 - HEATER CORE COOLANT SUPPLY LINES
5 - 58
BRAKES - BASE
PL/SRT-4
POWER BRAKE BOOSTER (Continued)
(4) Connect the power brake booster input rod-to-
brake pedal pin. Install a new retaining clip. Do not
use the old clip.
(5) Install and adjust a new brake lamp switch.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION)
(6) Connect all previously removed vacuum hoses
to the vacuum check valve (Fig. 106).
(7) 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.).
(8) If the vehicle is equipped with ABS, reinstall
the ICU. (Refer to 5 - BRAKES - ABS/HYDRAULIC/
MECHANICAL/ICU
(INTEGRATED
CONTROL
UNIT) - INSTALLATION).
(9) Install the master cylinder. For the master cyl-
inder installation procedure, (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER
CYL-
INDER - INSTALLATION).
(10) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 105). Tighten the two
bolts and nuts to a torque of 34 N·m (25 ft. lbs.)
(11) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 105).
(12) 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.
(13) Install the battery and clamp it in place.
(14) Connect
the
positive,
then
the
negative
(ground) cable on the battery.
(15) Bleed the base brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE)
(16) Road test the vehicle to ensure proper opera-
tion of the brakes.
INSTALLATION - RHD
(1) Position the brake booster on the dash panel by
reversing the path taken to remove the booster. Slide
the booster under the plenum on the battery tray
side of the engine compartment. Slide the booster
between the engine and dash panel until it can be
installed on the right side of the dash panel.
(2) Reinstall the vacuum supply hose on the
booster check valve. Make sure the booster check
valve is firmly seated in the rubber grommet and did
not become dislodged during the booster installation.
(3) If equipped, install the clutch master cylinder
through the dash panel.
(4) Install the clutch fluid reservoir. Torque the
retaining bolts to 7 N·m (62 in. lbs.).
(5) Working
from
underneath
the
instrument
panel, install the four brake booster retaining nuts.
Torque the nuts to 34 N·m (25 ft. lbs.).
(6) Grease the brake pedal pin and slide the brake
booster push rod onto the pedal pin. Install the
retaining clip.
(7) If equipped, lock the clutch master cylinder in
position. Rotate the clutch master cylinder to line up
the square shaped retaining boss with the square
shaped opening in the brake pedal support bracket.
Once the cylinder is inserted through the brake pedal
support bracket rotate 90° to lock it in position.
(8) Connect the clutch pedal push rod. Slide the
push rod on the clutch pedal mounted stud until the
plastic retention clip locks it in place.
(9) Install the coolant reservoir. Torque the retain-
ing bolts to 7 N·m (62 in. lbs.). Connect the coolant
overflow hose on the thermostat housing.
(10) Install the heater core coolant supply tube
support bracket bolts (Fig. 111). Torque the bolts to
36 N·m (27 ft. lbs.).
(11) Install the battery and battery tray in the
vehicle (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/TRAY - INSTALLATION).
(12) Install the air cleaner assembly (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION).
(13) Install the master cylinder on the vehicle.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
MASTER CYLINDER - INSTALLATION)
(14) Fill the brake fluid reservoir to specification.
(15) Bleed the air from the brake hydraulic system
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
WARNING:
Be
certain
a
firm
brake
pedal
is
achieved before attempting to move the vehicle.
PROPORTIONING VALVE
DESCRIPTION
NOTE: Only vehicles without antilock brakes have
proportioning valves. Vehicles with antilock brakes
have electronic variable brake proportioning (EVBP)
that is built into the integrated control unit (ICU).
Proportioning valves balance front to rear braking
by controlling the brake fluid hydraulic pressure to
the rear brakes. Under light pedal application, the
proportioning valve allows normal fluid flow to the
rear brakes. Under higher pedal effort, the valve
reduces fluid pressure to the rear brakes.
The non-antilock master cylinder is a four-outlet
design
with
two
screw-in
proportioning
valves
attached directly to the master cylinder housing (Fig.
112). One proportioning valve controls each rear
brake.
PL/SRT-4
BRAKES - BASE
5 - 59
POWER BRAKE BOOSTER (Continued)
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE
If premature rear wheel skid occurs on a hard
brake application, it could be an indication that a
malfunction has occurred with one of the proportion-
ing valves.
One proportioning valve controls the right rear
brake, and the other proportioning valve controls the
left rear brake (Fig. 112). Therefore, a road test to
determine which rear brake skids first is essential.
Before testing the proportioning valve in question,
inspect the rear brake linings for contamination or
for replacement shoes not meeting the OEM brake
lining material specifications.
The proportioning valve should always be tested
prior to being replaced.
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, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/PROPORTIONING
VALVE - DESCRIPTION).
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.
113), 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. 112).
(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. 114).
(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. 115).
(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
Fig. 112 Proportioning Valve Location
1 - RIGHT FRONT BRAKE TUBE
2 - LEFT FRONT BRAKE TUBE
3 - LEFT REAR BRAKE TUBE
4 - REAR PROPORTIONING VALVES
5 - RIGHT REAR BRAKE TUBE
Fig. 113 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
5 - 60
BRAKES - BASE
PL/SRT-4
PROPORTIONING VALVE (Continued)
the BRAKE PROPORTIONING VALVE APPLICA-
TIONS AND PRESSURE SPECIFICATIONS table
following this procedure. If the inlet gauge pressure
overshoots its target pressure when the pedal is
depressed, release the brake pedal, relieving the
pressure in the system, before reapplying the pedal
to reach the target pressure at the inlet gauge. This
is necessary to get an accurate reading of the outlet
pressure.
(10) Once inlet pressure has been achieved, check
the pressure reading on the proportioning valve out-
let gauge. If the proportioning valve outlet pressure
does not agree with value shown in the table, replace
the proportioning valve. If proportioning valve is
within pressure specifications, the valve is good and
does not require replacement.
(11) Reinstall the brake holding tool on the brake
pedal and remove the test equipment from the vehi-
cle.
(12) Remove the tools from the proportioning
valve.
(13) Install the proportioning valve in the master
cylinder and hand tighten until the proportioning
valve is fully installed and its O-ring seal is seated
into the master cylinder. Torque the proportioning
valve to 17.5 N·m (155 in. lbs.).
(14) Install the brake tube on the proportioning
valve. Torque the tube nut to 17 N·m (145 in. lbs.).
(15) Bleed the affected brake line. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS
Sales
Code
Brake System Type
Split Point
Slope
Identification
Inlet
Pressure
Outlet Pressure
BRA
14
9
Disc/Drum
300 psi
0.34
Red Band
1000 psi
480-580 psi
BRD
14
9
Disc/Disc
350 psi
0.34
Purple Band
1000 psi
525-625 psi
BRX
14
9
Disc/Disc
350 psi
0.34
Purple Band
1000 psi
525-625 psi
REMOVAL
NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).
(1) Using a brake pedal holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 116). 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) Disconnect the brake tube from the proportion-
ing valve requiring removal (Fig. 117).
(3) Unscrew the Proportioning valve from the mas-
ter cylinder.
INSTALLATION
NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).
Fig. 114 Tools On Valve
1 - PROPORTIONING VALVE
Fig. 115 Pressure Gauge Set
1 - SPECIAL TOOL C-4007–A
PL/SRT-4
BRAKES - BASE
5 - 61
PROPORTIONING VALVE (Continued)
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