Dodge Neon / Neon SRT-4. Manual — part 38
INSTALLATION
NOTE: Step 1 below is only required when installing
a caliper after new brake shoes have been installed.
(1) Completely retract the caliper piston back into
the bore of the caliper.
(2) Lubricate both steering knuckle caliper slide
abutments with a liberal amount of Mopar
t Multi-
purpose Lubricant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(3) 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. 61). 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.
(4) Install the caliper guide pin bolts and tighten
them to a torque of 22 N·m (192 in. lbs.) (Fig. 47).
(5) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 46). Install NEW washers
with the banjo bolt. Place one NEW washer on
each side of the hose fitting as the banjo bolt is
guided through the fitting. Thread the banjo bolt into
the caliper and tighten it to a torque of 24 N·m (210
in. lbs.).
(6) Install the tire and wheel assembly(Refer to 22
- TIRES/WHEELS - INSTALLATION). 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 5 -
BRAKES - STANDARD PROCEDURE)
(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 CALIPER -
FRONT - SRT-4
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
(1) Using a brake pedal holding tool, depress the
brake pedal past its first one inch of travel and
secure 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 LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the front tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 62). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Discard the
washers.
(5) Remove the two brake caliper guide pin bolts
(Fig. 62).
(6) Remove the disc brake caliper from the disc
brake adapter.
DISASSEMBLY
NOTE: Before disassembling the brake caliper,
remove it from the vehicle. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER -
REMOVAL)
NOTE: Before disassembling the brake caliper,
clean and inspect it. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPER -
CLEANING)(Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPER - INSPECTION)
Fig. 61 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
5 - 34
BRAKES - BASE
PL/SRT-4
DISC BRAKE CALIPER - FRONT (Continued)
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(1) Mount the caliper in a vise equipped with pro-
tective jaws.
(2) Place a wooden block in the caliper as shown
(Fig. 63).
WARNING: DO NOT PLACE FACE OR HANDS NEAR
CALIPER AND PISTON IF USING COMPRESSED AIR
PRESSURE TO REMOVE PISTON. DO NOT USE
HIGH PRESSURE.
(3) If necessary, apply low pressure compressed air
to the caliper fluid inlet in short spurts to force the
piston out.
(4) Remove the piston from the caliper.
(5) Remove the dust boot from the piston and dis-
card it.
CAUTION: Do not use a screw driver or other metal
tool for seal removal. Using such tools can scratch
the bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 64). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
with alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect both the piston and bore for scoring or
pitting. Bores that show light scratches or corrosion
can usually be cleared of the light scratches or corro-
sion using crocus cloth.
Fig. 62 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
Fig. 63 Piston Removal
1 - WOOD BLOCK
Fig. 64 Piston Seal Removal
1 - TRIM STICK
2 - SEAL
PL/SRT-4
BRAKES - BASE
5 - 35
DISC BRAKE CALIPER - FRONT - SRT-4 (Continued)
CLEANING - DISC BRAKE CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET
BRAKE
LININGS.
BREATHING
EXCESSIVE
CONCENTRATIONS
OF
ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE
CARE
WHEN
SERVICING
BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS
WITH
COMPRESSED AIR
OR
BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or Mopar
t Non-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - DISC BRAKE CALIPER
Inspect the disc brake caliper for the following:
• Brake fluid leaks in and around piston boot area
• Ruptures, brittleness or damage to the piston
dust boot
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY
NOTE: Always use new, clean Mopar
T
DOT 3 brake
fluid when assembling the brake caliper.
NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid
and install it in the groove of the caliper bore (Fig.
65). The seal should be started at one area of the
groove and gently worked around into the groove
using only your clean fingers to seat it.
(2) Coat the new piston with clean brake fluid.
(3) Coat the new piston boot with clean brake fluid
leaving a generous amount inside the boot.
(4) Position the dust boot over the lower section of
the piston (Fig. 66).
(5) Extend the dust boot below the bottom of the
piston and guide the lip seal into the groove in the
caliper piston bore.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(6) Install the piston into the bore carefully push-
ing it past the piston seal using hand pressure (Fig.
67). Push the piston in until it bottoms in the caliper
bore and the dust boot lip seal falls into the groove
near the top of the piston.
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPER -
INSTALLATION)
Fig. 65 New Piston Seal Installation
1 - SEAL
2 - GROOVE
Fig. 66 Boot Installation
5 - 36
BRAKES - BASE
PL/SRT-4
DISC BRAKE CALIPER - FRONT - SRT-4 (Continued)
INSTALLATION
CAUTION: When installing new brake components,
be sure to use correct parts. Parts designed for
BR3 Performance Brake System must not be mixed
with other brake systems. These parts can be easily
identified. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL
-
DESCRIPTION
-
DISC
BRAKES
(FRONT))
(1) Completely retract the caliper piston back into
the bore of the caliper. Use a C-clamp to retract the
piston. Place a wood block over the piston before
installing the C-clamp to avoid damaging the piston.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(2) Install the disc brake caliper over the brake
shoes on the brake caliper adapter. Make sure the
springs on the shoes do not get caught in the hole
formed into the center of the caliper housing.
(3) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
62).
(4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 62). Install NEW washers
on each side of the hose fitting as the banjo bolt is
guided through the fitting. Thread the banjo bolt into
the caliper and tighten it to a torque of 24 N·m (210
in. lbs.).
(5) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(6) Lower the vehicle.
(7) Remove the brake pedal holding tool.
(8) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - STANDARD PROCEDURE)
(9) 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 CALIPER GUIDE
PINS - FRONT - SRT-4
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 68).
(4) Remove the disc brake caliper from the disc
brake caliper adapter and hang it out of the way
using wire or a bungee cord. Use care not to overex-
tend the brake hose when doing this.
(5) Remove the guide pins and boots from the
adapter as shown (Fig. 69).
INSTALLATION
(1) Lubricate the guide pins and inside the boots
with the packet supplied with the service kit, Syth-
esco GLK-1 lubricant or equivalent.
(2) Install the guide pins and boots in the adapter
as shown (Fig. 69). The boots have grooves built into
their inner lips to fit onto the pins and adapter.
Fig. 67 Piston Installation
1 - PISTON GROOVE
Fig. 68 Brake Caliper Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
PL/SRT-4
BRAKES - BASE
5 - 37
DISC BRAKE CALIPER - FRONT - SRT-4 (Continued)
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