Dodge Neon / Neon SRT-4. Manual — part 31
CONDITION
POSSIBLE CAUSES
CORRECTION
4. Brake shoe lining transfer to brake
rotor.
4. Reface or replace brake rotors as
necessary. Replace brake shoes (pads).
EXCESSIVE PEDAL
EFFORT (HARD PEDAL -
CAN’T SKID WHEELS)
1. Power brake booster runout
(vacuum assist).
1. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)
1. Air in brake lines.
1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.
2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)
1. One of the two hydraulic circuits is
malfunctioning.
1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING
1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.
1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY
1. Air in brake lines.
1. Bleed brakes.
PREMATURE REAR
WHEEL LOCKUP
1. Contaminated brake shoe linings.
1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles only).
2. Test proportioning valves following
diagnosis and testing procedure. Refer
to Proportioning Valve. Replace valves
as necessary.
3. ABS EVBP not functioning.
3. Refer to the ABS section and
Appropriate Diagnostic Information.
STOP LAMPS STAY ON
1. Brake lamp switch out of
adjustment.
1. Replace brake lamp switch and
adjust. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
2. Brake pedal binding.
2. Inspect and replace as necessary.
3. Power Brake Booster not allowing
pedal to return completely.
3. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING
1. Frozen brake caliper piston.
1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining
(most likely front linings).
2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines.
3. Replace pinched line.
4. Leaking piston seal.
4. Replace piston seal or brake caliper.
5. Suspension problem.
5. Refer to the Suspension group.
5 - 6
BRAKES - BASE
PL/SRT-4
BRAKES - BASE (Continued)
CONDITION
POSSIBLE CAUSES
CORRECTION
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL
1. Rear brakes out of adjustment.
1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: For bleeding the ABS hydraulic system, refer
to Antilock Brake System Bleeding in the Antilock
Brake System section.
CAUTION: Before removing the master cylinder cap,
wipe it clean to prevent dirt and other foreign mat-
ter from dropping into the master cylinder reservoir.
CAUTION: Use only Mopar
T
brake fluid or an equiv-
alent from a fresh, tightly sealed container. Brake
fluid must conform to DOT 3 specifications.
Do not pump the brake pedal at any time while a
bleeder screw is open. This will only increase the
amount of air in the system and make additional
bleeding necessary.
Do not allow the master cylinder reservoir to run
out of brake fluid while bleeding the system. An
empty reservoir will allow additional air into the
brake system. Check the fluid level frequently and
add fluid as needed.
The following wheel circuit sequence for bleeding
the brake hydraulic system should be used to ensure
adequate removal of all trapped air from the hydrau-
lic system.
• Left rear wheel
• Right front wheel
• Right rear wheel
• Left front wheel
MANUAL BLEEDING
NOTE: To bleed the brakes manually, the aid of a
helper will be required.
(1) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 1).
(2) Have a helper pump the brake pedal three or
four times and hold it in the down position.
(3) With the pedal in the down position, open the
bleeder screw at least 1 full turn.
(4) Once the brake pedal has dropped, close the
bleeder screw. After the bleeder screw is closed,
release the brake pedal.
(5) Repeat the above steps until all trapped air is
removed from that wheel circuit (usually four or five
times).
(6) Bleed the remaining wheel circuits in the same
manner until all air is removed from the brake sys-
tem. Monitor the fluid level in the master cylinder
reservoir to make sure it does not go dry.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
PRESSURE BLEEDING
NOTE:
Follow
pressure
bleeder
manufacturer’s
instructions for use of pressure bleeding equip-
ment.
Following the same wheel circuit sequence as pre-
scribed for manual bleeding.
(1) Attach Adapter, Special Tool 6921, to the mas-
ter cylinder reservoir (Fig. 2).
(2) Attach Bleeder Tank, Special Tool C-3496-B, or
an equivalent, to the adapter on the master cylinder.
(3) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
Fig. 1 Proper Method for Purging Air From Brake
System (Typical)
1 - CLEAR HOSE
2 - BRAKE CALIPER
3 - BLEEDER SCREW
4 - CLEAN BRAKE FLUID
PL/SRT-4
BRAKES - BASE
5 - 7
BRAKES - BASE (Continued)
fresh brake fluid to submerge the end of the hose
(Fig. 1).
(4) Open the bleeder screw at least one full turn or
more to obtain a steady stream of brake fluid.
(5) After approximately 4–8 ounces of fluid have
been bled through the brake circuit and an air-free
flow is maintained in the clear plastic hose and jar,
close the bleeder screw.
(6) Repeat this procedure at all the remaining
bleeder screws.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
SPECIFICATIONS
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power
Brakes
Standard
Hydraulic System
Dual-Diagonally Split
BRAKE PEDAL:
Pedal Ratio
3.41
POWER BRAKE BOOSTER:
Make/Type
Bosch/Vacuum
Mounting Studs
M8 x 1.25
Diaphragm Size/Type
205 mm Tandem
MASTER CYLINDER ASSEMBLY:
Type
Dual Tandem
ACTUATION:
Body Material
Anodized Aluminum
Reservoir Material
Polypropelene
MASTER CYLINDER BORE STROKE AND SPLIT:
Non ABS
22.23 mm x 34.0 mm
(0.875 in. x 1.34 in.)
ABS
23.82 mm x 34.0 mm
(0.937 in. x 1.34 in.)
Displacement Split
50 / 50
MASTER CYLINDER FLUID OUTLET PORTS:
Tube Fitting Type
SAE 45° Inverted Flare
W/ABS - Primary Tube
Nut Thread
7/16 in.–24
W/ABS - Secondary Tube
Nut Thread
3/8 in.–24
W/O ABS - All Tube Nut
Threads
7/16 in.–24
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting
Type
SAE 45° Inverted Flare
Inlet Port Threads
7/16 in.–24
Outlet Port Threads-Left
Front and Left Rear
7/16 in.–24
Outlet Port Threads-Right
Front and Right Rear
3/8 in.–24
PROPORTIONING VALVES: (non-ABS vehicles)
Material
Aluminum
Function
Fixed Pressure
Proportioning
BRAKE FASTENER TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
ABS ICU Mounting Bolts (To
Bracket)
11
8
97
ABS ICU Mounting Bracket
Bolts (To Frame)
23
17
200
ABS CAB Mounting Screws
(To HCU)
2
—
17
ABS Wheel Speed Sensor
Mounting Screw
12
9
105
Brake Hose Banjo Bolt (To
Caliper)
24
18
210
Brake Tube Nuts
17
12
145
Disc Brake Caliper Adapter
(To Knuckle) - Front - SRT-4
104
77
—
Fig. 2 Special Tool 6921
1 - MASTER CYLINDER
5 - 8
BRAKES - BASE
PL/SRT-4
BRAKES - BASE (Continued)
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Disc Brake Caliper Adapter
(To Knuckle) - Rear
75
55
—
Disc Brake Caliper Guide
Pin Bolts
22
16
192
Disc Brake Caliper Guide
Pin Bolts - Front - SRT-4
35
26
—
Disc Brake Caliper Bleeder
Screw
15
11
125
Drum Brake Shoe Support
Plate Mounting Bolts
75
55
—
Drum Brake Wheel Cylinder
Mounting Bolts
13
10
115
Drum Brake Wheel Cylinder
Bleeder Screw
10
7
89
Master Cylinder Mounting
Nuts
18
13
160
Parking Brake Lever
Mounting Nut And Screw
28
21
250
Power Brake Booster
Mounting Nuts
34
25
300
Wheel Mounting (Lug) Nuts
135
100
—
SPECIAL TOOLS
BASE BRAKE SYSTEM
Adapters, Brake Pressure 6805
Adapter, Brake Pressure 8644
Gauge Set C-4007-A
Handle, Universal C-4171
Installer, Dust Boot C-4689
Dial Indicator C-3339
Tubes, Master Cylinder Bleed 8358
PL/SRT-4
BRAKES - BASE
5 - 9
BRAKES - BASE (Continued)
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