Dodge Neon / Neon SRT-4. Manual — part 42

(5) Disconnect the two brake tubes from the mas-

ter cylinder, and two brake tubes from the propor-
tioning valves (Fig. 96). Install plugs at all of the
open brake tube outlets on the master cylinder.

(6) Clean the area around where the master cylin-

der attaches to the power brake booster using a suit-
able brake cleaner such as Mopar Brake Parts
Cleaner or an equivalent.

(7) Remove the two nuts attaching the master cyl-

inder to the power brake booster.

(8) Slide the master cylinder straight out of the

power brake booster.

(9) To remove the proportioning valves, unthread

each from the master cylinder.

REMOVAL - RHD

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING).

CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.

(1) With the engine not running, pump the brake

pedal 4-5 strokes until the pedal feel is firm.

(2) Disconnect the negative (ground) cable from

the battery and isolate the cable.

(3) Disconnect the brake fluid level switch wiring

connector (Fig. 97).

(4) Remove the brake lines from the master cylin-

der.

(5) Remove the (2) master cylinder mounting nuts.
(6) Slide the master cylinder assembly straight out

of the power brake booster.

INSTALLATION

INSTALLATION - LHD WITH ABS

NOTE: The master cylinder must be bled before
installing it on the vehicle.

(1) Bleed the master cylinder before installing it

on the vehicle. (Refer to 5 - BRAKES - ABS/HY-
DRAULIC/MECHANICAL/MASTER

CYLINDER

-

STANDARD PROCEDURE).

(2) Inspect and wipe clean the O-ring vacuum seal

on the master cylinder rear mounting flange to
ensure a good vacuum seal once installation is com-
plete. Replace as necessary.

(3) Wipe the face of the power brake booster clean

where the master cylinder seal comes in contact
when it’s installed. Do not get any cleaner or debris
inside the booster.

(4) Position the master cylinder on the studs of

power brake vacuum booster aligning the booster
push rod with the master cylinder push rod. Care-
fully push the master cylinder onto the studs until it
contacts the face of the booster.

Fig. 96 Brake Tubes At 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

Fig. 97 RHD MASTER CYLINDER

1 - POWER BRAKE VACUUM BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - MASTER CYLINDER
4 - BRAKE FLUID RESERVOIR

5 - 50

BRAKES - BASE

PL/SRT-4

MASTER CYLINDER (Continued)

(5) Install the two master cylinder mounting nuts

(Fig. 94). Tighten the mounting nuts to a torque of
18 N·m (160 in. lbs.).

(6) Connect the primary and secondary brake

tubes to the master cylinder primary and secondary
ports (Fig. 94). Tighten the nuts to a torque of 17
N·m (145 in. lbs.).

(7) Install the wiring harness connector on the

master cylinder reservoir fluid level switch.

(8) Install the battery and clamp in place.
(9) Connect

the

positive,

then

the

negative

(ground) cable on the battery.

(10) Fill the master cylinder to the proper level.
(11) Pump the brake pedal several times, then

check brake fluid level in master cylinder reservoir.
Adjust brake fluid level as necessary.

CAUTION: It will be necessary to bleed the entire
base hydraulic system if the brake system has been
open to air for an excessive amount of time or air is
present in the lines. (Refer to 5 - BRAKES - STAN-
DARD PROCEDURE)

(12) Check for leaks.
(13) Road test the vehicle to ensure proper opera-

tion of the base and antilock brake systems.

INSTALLATION - LHD WITHOUT ABS

NOTE: The master cylinder must be bled before
installing it on the vehicle.

(1) If removed, install the proportioning valves in

their master cylinder ports. The valves are identical,
so they can be installed in either master cylinder
port going to the rear brakes. Make sure the O-rings
on the proportioning valves are new.

(2) Bleed the master cylinder before installing it

on the vehicle. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - STANDARD
PROCEDURE).

(3) Inspect and wipe clean the O-ring vacuum seal

on the master cylinder rear mounting flange to
ensure a good vacuum seal once installation is com-
plete. Replace as necessary.

(4) Wipe the face of the power brake booster clean

where the master cylinder seal comes in contact
when it’s installed. Do not get any cleaner or debris
inside the booster.

(5) 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.

(6) Install the two master cylinder mounting nuts

and tighten each to a torque of 18 N·m (160 in. lbs.).

(7) Connect the four brake tubes to the master cyl-

inder and proportioning valve ports (Fig. 96). Tighten
all tube nuts to a torque of 17 N·m (145 in. lbs.).

(8) Connect the brake fluid level switch wiring

connector.

(9) Install the battery and clamp it in place.
(10) Connect

the

positive,

then

the

negative

(ground) cable on the battery.

(11) Fill the master cylinder to the proper level.
(12) Pump the brake pedal several times, then

check brake fluid level in master cylinder reservoir.
Adjust brake fluid level as necessary.

CAUTION: It will be necessary to bleed the entire
base hydraulic system if the brake system has been
open to air for an excessive amount of time or air is
present in the lines. (Refer to 5 - BRAKES - STAN-
DARD PROCEDURE)

(13) Check for leaks.
(14) Road test the vehicle to ensure proper opera-

tion of the brakes.

INSTALLATION - RHD

NOTE: The master cylinder must be bled before
installing it on the vehicle.

(1) If removed, install the proportioning valves in

their master cylinder ports. The valves are identical,
so they can be installed in either master cylinder
port going to the rear brakes. Make sure the O-rings
on the proportioning valves are new.

(2) Bleed the master cylinder before installing it

on the vehicle. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - STANDARD
PROCEDURE).

(3) Inspect and wipe clean the O-ring vacuum seal

on the master cylinder rear mounting flange to
ensure a good vacuum seal once installation is com-
plete. Replace as necessary.

(4) Wipe the face of the power brake booster clean

where the master cylinder seal comes in contact
when it’s installed. Do not get any cleaner or debris
inside the booster.

(5) Slide the master cylinder assembly straight in

the power brake booster.

(6) Install the (2) master cylinder retaining nuts.

Torque the nuts to 18 N·m (160 in. lbs.).

(7) Install the brake lines on the master cylinder.

Torque the tube nuts to 17 N·m (145 in. lbs.).

(8) Connect the brake fluid level switch wiring

connector (Fig. 97).

(9) Fill the master cylinder to the proper level.
(10) Pump the brake pedal several times, then

check brake fluid level in master cylinder reservoir.
Adjust brake fluid level as necessary.

PL/SRT-4

BRAKES - BASE

5 - 51

MASTER CYLINDER (Continued)

CAUTION: It will be necessary to bleed the entire
base hydraulic system if the brake system has been
open to air for an excessive amount of time or air is
present in the lines. (Refer to 5 - BRAKES - STAN-
DARD PROCEDURE)

(11) Check for leaks.
(12) Road test the vehicle to ensure proper opera-

tion of the brakes.

PEDAL

REMOVAL

NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).

WITH AUTOMATIC TRANSAXLE

(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. 98). 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. 99) (the
pinch bolt nut is caged to the coupling and is not
removable). Separate the upper and lower steering
column couplings.

(4) Remove the brake lamp switch. (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

-

EXTERIOR/

BRAKE LAMP SWITCH - REMOVAL)

(5) Remove the clip securing the power brake

booster input rod to the brake pedal. Remove the
input rod from the brake pedal.

(6) Remove the two upper nuts fastening the brake

pedal bracket to the power brake booster (Fig. 100).

(7) Carefully pry the tie bar running between the

two upper booster mounting studs from its plastic
retaining fasteners.

(8) Remove the two remaining nuts fastening the

brake pedal bracket to the power brake booster (Fig.
100).

Fig. 98 Steering Wheel Holder

1 - STEERING WHEEL
2 - STEERING WHEEL HOLDER
3 - DRIVERS SEAT

Fig. 99 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. 100 Brake Pedal Mounting

1 - CLUTCH CABLE
2 - BOOSTER MOUNTING NUTS
3 - UPPER MOUNTING NUTS

5 - 52

BRAKES - BASE

PL/SRT-4

MASTER CYLINDER (Continued)

(9) If the vehicle is equipped with antilock brakes,

carefully push the power brake booster forward until
the booster contacts the ABS ICU mounting bracket.

(10) 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.

(11) Remove the two nuts fastening the brake

pedal bracket to the instrument panel support (Fig.
100).

(12) 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.

(13) 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.

WITH MANUAL TRANSAXLE

(1) Remove the instrument panel. (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - REMOVAL).

(2) Remove the brake lamp switch. (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

-

EXTERIOR/

BRAKE LAMP SWITCH - REMOVAL)

(3) Disconnect the clutch cable from the clutch

pedal spacer (Fig. 101).

(4) Disconnect the wiring harness connector going

to the clutch pedal switches (Fig. 102).

(5) Remove the clip securing the power brake

booster input rod to the brake pedal. Remove the
input rod from the brake pedal.

(6) Remove the four nuts fastening the brake pedal

bracket to the power brake booster (Fig. 100).

(7) Remove the two nuts fastening the brake pedal

bracket to the instrument panel support (Fig. 100).

(8) Remove the brake pedal assembly.
(9) 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

NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).

WITH AUTOMATIC TRANSAXLE

(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.

Fig. 101 Clutch Cable Connection

1 - SNAP RING
2 - CLUTCH PEDAL SPACER
3 - CLUTCH PEDAL
4 - CLUTCH CABLE

Fig. 102 Wiring Harness Connector

1 - UPSTOP SWITCH
2 - CLUTCH PEDAL
3 - INTERLOCK SWITCH
4 - CONNECTOR

PL/SRT-4

BRAKES - BASE

5 - 53

PEDAL (Continued)