Dodge Neon / Neon SRT-4. Manual — part 41

INSTALLATION

NOTE: Before installing the drum, inspect the brake
shoe linings for wear, shoe alignment, and contam-
ination.

(1) Install the rear brake drum on rear hub and

bearing (Fig. 88).

(2) Install the tire and wheel assembly (Refer to 22

- TIRES/WHEELS - REMOVAL). Tighten the wheel
mounting nuts to a torque of 135 N·m (100 ft. lbs.).

(3) Adjust the rear brake shoes as necessary.

(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - ADJUSTMENTS).

(4) Lower the vehicle.

FLUID

DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION

Indications of fluid contamination are swollen or

deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.

To test for contamination, put a small amount of

drained brake fluid in clear glass jar. If the fluid sep-
arates into layers, there is mineral oil or other fluid
contamination of the brake fluid.

If the brake fluid is contaminated, drain and thor-

oughly flush the brake system. Replace all the rubber
parts or components containing rubber coming into
contact with the brake fluid including: the master
cylinder and reservoir; proportioning valves (non-
ABS);

caliper

seals;

wheel

cylinder

seals; ABS

hydraulic control unit; and all hydraulic fluid hoses.

STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING

Brake fluid level should be checked a minimum of

twice a year.

Master cylinder reservoirs are marked, FULL and

MIN, indicating the allowable brake fluid level range
in the master cylinder brake fluid reservoir (Fig. 89).

CAUTION: Use only Mopar

T

brake fluid or an equiv-

alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.

Although there is a range, the preferred level is

FULL. If necessary, adjust the brake fluid level to

the FULL mark on the side of the master cylinder
brake fluid reservoir.

SPECIFICATIONS

BRAKE FLUID

The brake fluid used in this vehicle must conform

to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar

t Brake Fluid or an equivalent from a

tightly sealed container.

CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.

CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.

Fig. 89 Master Cylinder

1 - POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 - POWER BRAKE BOOSTER
3 - BRAKE FLUID LEVEL SWITCH
4 - MASTER CYLINDER

5 - 46

BRAKES - BASE

PL/SRT-4

DRUM (Continued)

FLUID RESERVOIR

REMOVAL

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

NOTE: The master cylinder does not need to be
removed from the power brake booster for removal
and installation of the brake fluid reservoir.

(1) Clean the master cylinder housing and brake

fluid reservoir exterior surfaces.

(2) Remove the brake fluid reservoir cap. Using a

clean syringe or siphoning tool, empty as much brake
fluid as possible from the reservoir.

(3) Remove the vehicle wiring harness connector

from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 95).

(4) Remove the two plastic pins holding the reser-

voir to the master cylinder (Fig. 90).

(5) Lift the reservoir from the master cylinder

casting.

(6) Remove the grommets (O-rings) sealing the

reservoir to the master cylinder housing (Fig. 91).

INSTALLATION

(1) Install NEW sealing grommets (O-rings) in the

master cylinder housing (Fig. 91).

(2) Lubricate the sealing grommets with fresh

clean DOT 3 brake fluid. Place the reservoir in posi-
tion over the grommets making sure the filler hole is
towards the front of the vehicle. Seat the reservoir
into the grommets. While holding the reservoir firmly
against the grommets, install new plastic pins

through their mounting holes until they protrude out
the other side of the master cylinder reservoir (Fig.
90).

(3) Connect the brake fluid level switch wiring

connector (Fig. 95).

(4) Fill the reservoir with fresh clean DOT 3 brake

fluid. (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/FLUID - STANDARD PROCEDURE).

MASTER CYLINDER

DESCRIPTION

Two different master cylinders are used on this

vehicle. Vehicles without antilock brakes (ABS) use a
standard compensating-port master cylinder, while
vehicles equipped with ABS use a center-valve design
master cylinder.

ABS vehicles, equipped with rear disc brakes, use

a master cylinder with a 23.82 mm (0.937 in.) bore
diameter, while non-ABS vehicles, equipped with
rear disc brakes, use a 22.23 mm (0.875 in.) bore
diameter master cylinder.

The ABS master cylinder is a two-outlet design

and the brake tubes from these primary and second-
ary outlet ports lead directly to the integrated control
unit (ICU) before going to each wheel brake (Fig. 94).

The non-ABS master cylinder is a four-outlet

design (one for each wheel brake) with two screw-in
proportioning valves (one for each rear wheel brake).
One is attached directly to the inboard side of the
master cylinder housing while the other is attached
to the bottom (Fig. 96).

Both type master cylinders mount to the power

brake booster using two nuts. They both have a seal

Fig. 90 Master Cylinder Reservoir

1 - BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 - RESERVOIR RETAINING PINS
3 - SEAL

Fig. 91 Sealing Grommets

1 - MASTER CYLINDER
2 - GROMMETS (O-RINGS)
3 - SEAL

PL/SRT-4

BRAKES - BASE

5 - 47

on the rear of the mounting flange to seal vacuum in
the booster.

The master cylinder body is an anodized aluminum

casting. It has a machined bore to accept the master
cylinder piston and also has threaded ports with
seats for hydraulic brake line connections.

The master cylinder has the brake fluid reservoir

mounted on top of it which gravity feeds brake fluid
to the master cylinder when it is required. The res-
ervoir is made of see-through plastic and it houses
the brake fluid level switch. A removable brake fluid
level switch is mounted in the left side.

OPERATION

When the brake pedal is pressed, the master cylin-

der primary and secondary pistons apply brake pres-
sure through the proportioning valves (on non-ABS
vehicles) and chassis brake tubes to each brake
assembly. The brake fluid reservoir supplies the
brake hydraulic system with the necessary fluid to
operate properly.

The non-ABS master cylinder’s primary outlet

ports supply hydraulic pressure to the right front
and left rear brakes while the secondary outlet ports
supply hydraulic pressure to the left front and right
rear brakes. ABS equipped master cylinder outlet
ports supply hydraulic pressure to the ABS Inte-
grated Control Unit (ICU) where it is distributed to
the individual wheel brakes.

The master cylinder reservoir cap diaphragm is slit

to allow atmospheric pressure to equalize on both
sides of the diaphragm.

STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING

(1) Clamp the master cylinder in a vise.
(2) Refer to one of the following depending on

whether the master cylinder is a non-ABS unit Step
a or an ABS unit Step b:

(a) Attach four Master Cylinder Bleed Tubes,

Special Tool 8358-1, to the four ports of the master
cylinder and tighten each in place (Fig. 92). The
bleed tubes for the ports pertaining to the rear
brakes are made to attach to the proportioning
valves screwed into the master cylinder. Position
the other end of the tubes into the master cylinder
reservoir so their outlets are below the surface of
the brake fluid in the reservoir when filled.

(b) Attach Master Cylinder Bleed Tube, Special

Tool 8358-1, to the primary port of the master cyl-
inder and tighten in place (Fig. 93). Attach Master
Cylinder Bleed Tube, Special Tool 8358-2, to the
secondary port of the master cylinder and tighten
in place. Position the other end of the tubes into
the master cylinder reservoir so their outlets are

below the surface of the brake fluid in the reservoir
when filled.

(3) Fill the brake fluid reservoir with fresh Mopar

t

brake fluid, or equivalent conforming to DOT 3 spec-
ifications.

(4) Using a wooden dowel as a pushrod (Fig. 92)

(Fig. 93), press the pistons inward slowly applying
brake pressure, then release the pressure, allowing
the pistons to return to the released position. Repeat
this several times until all air bubbles are expelled
out of the tubes and master cylinder bore.

(5) Remove the bleed tubes from the master cylin-

der and plug the outlet ports.

(6) Install the fill cap on the reservoir.
(7) Remove the master cylinder from the vise.

Fig. 92 Bleeding Master Cylinder - W/O ABS

1 - WOODEN DOWEL
2 - MASTER CYLINDER

Fig. 93 Bleeding Master Cylinder - W/ABS

1 - WOODEN DOWEL
2 - MASTER CYLINDER

5 - 48

BRAKES - BASE

PL/SRT-4

MASTER CYLINDER (Continued)

REMOVAL

REMOVAL - LHD WITH ABS

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 positive cable from the battery,

then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.

(4) Disconnect the wiring harness connector from

the brake fluid level switch on the master cylinder
reservoir (Fig. 94).

(5) Disconnect the primary and secondary brake

tubes from master cylinder (Fig. 94). Install plugs in
the master cylinder outlet ports.

(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

t Brake Parts

Cleaner or an equivalent.

(7) Remove the 2 nuts attaching master cylinder to

power brake booster (Fig. 94).

(8) Slide the master cylinder straight out of the

power brake booster.

REMOVAL - LHD WITHOUT ABS

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

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 positive cable from the battery,

then remove the battery from the battery tray. There

is one nut securing the clamp on the backside of the
battery holding it in place.

(4) Remove the vehicle wiring harness connector

from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 95).

Fig. 94 Master Cylinder - W/ABS

1 - POWER BRAKE BOOSTER
2 - CONNECTOR
3 - BRAKE FLUID LEVEL SWITCH
4 - MOUNTING NUTS
5 - SECONDARY BRAKE TUBE
6 - PRIMARY BRAKE TUBE

Fig. 95 Master Cylinder

1 - POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 - POWER BRAKE BOOSTER
3 - BRAKE FLUID LEVEL SWITCH
4 - MASTER CYLINDER

PL/SRT-4

BRAKES - BASE

5 - 49

MASTER CYLINDER (Continued)