Dodge Neon / Neon SRT-4. Manual — part 33

DESCRIPTION - DISC BRAKES (REAR)

Rear disc brakes are optional equipment on some

models of this vehicle (Fig. 14). The rear disc brakes
are similar to the front disc brakes; however, there
are several distinctive features that require different
service procedures. The rear disc brakes consist of
the following components:

• Brake caliper - single-piston, floating type

• Brake caliper adapter

• Brake shoe and linings

• Brake rotor - drum-in-hat type
All vehicles equipped with rear disc brakes have a

small duo-servo drum brake mounted to the caliper
adapter. This is part of the parking brake system.
The drum brake shoes expand out against a braking
surface (hat section) on the inside area of the disc
brake rotor.

Vehicles are equipped with a caliper assembly that

has a 34 mm (1.43 in.) piston and uses a solid non-
vented rotor.

The caliper assembly for all applications floats on

rubber bushings using internal metal sleeves that
are attached to the adapter using threaded guide pin
bolts.

The brake caliper adapter and rotor shield are

mounted to the rear suspension knuckles of vehicle.
The adapter is used to mount the brake caliper to the
vehicle (Fig. 14). The adapter has two machined
abutments, which are used to position and align the
caliper and brake pads for movement inboard and

outboard. The adapter also mounts the parking brake
shoes and actuating cables to the vehicle.

DESCRIPTION - DISC BRAKES (REAR) - SRT-4

Rear disc brakes are standard on this vehicle (Fig.

14). The sales code for this performance brake sys-
tem is BR3. Each rear disc brake consists of the fol-
lowing components:

• Caliper - single-piston, floating type

• Caliper adapter

• Shoe and lining assemblies (Pads)

• Rotor - drum-in-hat type
BR3 rear disc brakes are similar to and operate

the same as standard PL brakes, but differ in the fol-
lowing ways. Like the standard PL with rear disc
brakes, vehicles with BR3 rear disc brakes are
equipped with a one piece caliper assembly that has
a 36 mm (1.42 in.) piston and use a solid non-vented
270 mm (10.63 in.) drum-in-hat brake rotor. But
unlike the standard PL, the BR3 rear disc brake cal-
iper is painted red. Also, the BR3 rear disc brake
rotor has a pad contact surface approximately 3 mm
thicker than the standard PL. BR3 brake rotors can
be easily identified by the recessed machined area
near the hub center (Fig. 15).

To accommodate the additional width brake rotors,

instead of using wider calipers, each rear brake shoe
metal backing plate is 1.5 mm thinner than that of
the standard PL with rear disc brakes (Fig. 16).
When replacing brake shoes, often referred to as
pads, only brake shoes meeting the original equip-
ment manufacturer (OEM) formulation (such as
Mopar

t replacement parts) should be used.

NOTE: Special care should be taken to assure that
the correct brake shoes are used only with the cor-
rect rotor.

As with the standard PL rear disc brakes, the BR3

caliper adapter is mounted to the rear suspension
spindle. The adapter is used to mount the disc brake
caliper to the vehicle (Fig. 14).

DESCRIPTION - DRUM BRAKES (REAR)

Rear drum brakes are standard equipment on this

vehicle. The rear drum brakes consist of the major
components listed in the figure (Fig. 17). Other com-
ponents related to the brake shoes themselves can be
seen in the next figure (Fig. 18).

The rear wheel drum brakes are a two-shoe, inter-

nal-expanding type with an automatic adjuster screw
(Fig. 18). The automatic adjuster screw is actuated
each time the brakes are applied and adjustment is
made when lining wear permits. The automatic
adjuster screw is located directly below the rear
brake wheel cylinder.

Fig. 14 Rear Disc Brakes

1 - DISC BRAKE CALIPER
2 - DISC BRAKE ADAPTER
3 - GUIDE PIN BOLTS
4 - HUB AND BEARING
5 - BRAKE ROTOR
6 - RETAINER CLIP
7 - DUST CAP
8 - NUT

5 - 14

BRAKES - BASE

PL/SRT-4

HYDRAULIC/MECHANICAL (Continued)

Fig. 15 Rear Brake Rotor Comparison

1 - STANDARD PL BRAKE ROTOR
2 - STANDARD ROTOR THICKNESS
8.75-9.25 MM
3 - PERFORMANCE ROTOR THICKNESS
11.75-12.25 MM
4 - BR3 PERFORMANCE BRAKE ROTOR
5 - INDENTIFYING MACHINED AREA

Fig. 16 Standard And BR3 Brake Shoes

1 - BRAKE CALIPER WITH STANDARD SHOES
2 - BRAKE CALIPER WITH BR3 SHOES
3 - 4.5 MM
4 - 6.0 MM

Fig. 17 Rear Drum Brakes

1 - DUST CAP
2 - NUT
3 - DRUM
4 - HUB AND BEARING
5 - WHEEL CYLINDER
6 - SEAL
7 - SUPPORT PLATE
8 - BRAKE SHOES
9 - RETAINER CLIP

Fig. 18 Drum Brake Shoes (Left Side Shown)

1 - WHEEL CYLINDER
2 - AUTOMATIC ADJUSTER SCREW ASSEMBLY
3 - RETURN SPRING
4 - HOLD DOWN CLIP
5 - HOLD DOWN CLIP
6 - AUTOMATIC ADJUSTER LEVER AND SPRING
7 - PARK BRAKE LEVER
8 - PARK BRAKE CABLE
9 - FRONT BRAKE SHOE
10 - BRAKESHOE TO ANCHOR SPRING
11 - BRAKE ANCHOR PLATE
12 - REAR BRAKE SHOE

PL/SRT-4

BRAKES - BASE

5 - 15

HYDRAULIC/MECHANICAL (Continued)

DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER

To

properly

test

the

drum

brake

automatic

adjuster, the aide of a helper inside the vehicle to
apply the brakes will be necessary.

(1) Raise the vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove the access plug from the rear adjust-

ment slot in each brake support plate.

(3) Insert a thin screwdriver in the adjustment

slot and push back the adjustment lever. With the
lever in this position, back the star wheel adjustment
off approximately 10 notches. This will eliminate the
possibility that the brake is at full adjustment, and
can be adjusted no further.

(4) Remove the screwdriver from the adjustment

slot.

(5) Watch the star wheel through the adjustment

slot, while a helper applies the brake pedal. As the
brake shoes apply, the adjustment lever should move
downward, turning the star wheel. A definite rotation
of the adjuster star wheel can be observed if the
automatic adjuster is working properly.

If the star wheel does not move as indicated, the

brake drum needs to be removed and further inspec-
tion of the rear brakes is necessary.

(6) If the star wheel is operating properly, readjust

the brakes. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE

PADS/SHOES

-

ADJUST-

MENTS).

(7) Reinstall the adjustment slot access plug.
(8) Lower the vehicle.

BRAKE LINES

DESCRIPTION - BRAKE TUBES AND HOSES

The brake tubes are steel with a corrosion-resis-

tant nylon coating applied to the external surfaces.
The flex hoses are made of reinforced rubber with fit-
tings at each end.

OPERATION - BRAKE TUBES AND HOSES

The purpose of the brake tubes and flex hoses is to

transfer brake fluid pressure, developed by the mas-
ter cylinder to the brakes at each wheel of the vehi-
cle. The flex hoses connect the chassis brake tubes
which are mounted to the vehicle’s underbody to the
brake at each wheel, allowing for movement of the
vehicle’s suspension.

INSPECTION - BRAKE TUBES AND HOSES

Flexible rubber hose is used at both front and rear

brakes. Inspection of brake hoses should be per-
formed whenever the brake system is serviced and

every 7,500 miles or 12 months, whichever comes
first (every engine oil change). Inspect hydraulic
brake hoses for severe surface cracking, scuffing,
worn spots or physical damage. If the fabric casing of
the rubber hose becomes exposed due to cracks or
abrasions in the rubber hose cover, the hose should
be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure.
Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.

The steel brake tubing should be inspected period-

ically for evidence of corrosion, physical damage or
contact with moving or hot components of the vehi-
cle.

BRAKE PADS/SHOES - FRONT

REMOVAL

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

NOTE: Some vehicles use a different lining material
on the front disc brake shoes than other vehicles.
When new brake shoes are installed, be sure the
brake shoes for the correct type of brake system
are used.

(1) Raise the vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove both front tire and wheel assemblies

from vehicle (Refer to 22 - TIRES/WHEELS -
REMOVAL).

(3) Begin on one side of the vehicle.

NOTE: In some cases, it may be necessary to
retract the caliper piston in its bore a small amount
in order to provide sufficient clearance between the
shoes and the rotor to easily remove the caliper
from the knuckle. This can usually be accomplished
before the guide pin bolts are removed, by grasping
the rear of the caliper and pulling outward working
with the guide pins, thus retracting the piston.
Never push on the piston directly as it may get
damaged.

(4) Remove the two brake caliper guide pin bolts

(Fig. 19).

(5) Remove the disc brake caliper from the steer-

ing knuckle. The caliper is removed by first tipping
either the top (right side caliper) or bottom (left side
caliper) of the caliper away from the brake rotor,
then pulling the caliper off the opposite end’s caliper
slide abutment (on the knuckle) and brake rotor.

5 - 16

BRAKES - BASE

PL/SRT-4

HYDRAULIC/MECHANICAL (Continued)

(6) Support the caliper using a wire or cord to pre-

vent the weight of caliper from damaging the brake
hose (Fig. 20). Do not let the caliper hang by the
brake hose.

(7) Remove the outboard brake shoe from the cali-

per by prying the shoe retaining clip over the raised
area on the caliper. Slide the brake shoe down and
off of the caliper (Fig. 21).

(8) Pull the inboard brake shoe away from the cal-

iper piston until the retaining clip is out of the cavity
in the piston (Fig. 22) and remove the shoe.

(9) Repeat the above procedure to the front brakes

on the other side of the vehicle.

Fig. 19 Caliper And Rotor Mounting

1 - RETAINER CLIP
2 - BRAKE ROTOR
3 - HUB
4 - GUIDE PIN BOLTS
5 - DISC BRAKE CALIPER

Fig. 20 Supporting Caliper

1 - WIRE HANGER
2 - STEERING KNUCKLE
3 - BRAKE DISC
4 - DISC BRAKE CALIPER ASSEMBLY
5 - BRAKE HYDRAULIC HOSE

Fig. 21 Removing Outboard Brake Shoe

1 - CALIPER ASSEMBLY
2 - HANGER WIRE
3 - BRAKE FLEX HOSE
4 - OUTBOARD BRAKE PAD
5 - HUB/BEARING ASSEMBLY
6 - STEERING KNUCKLE
7 - SCREWDRIVER

Fig. 22 Removing Inboard Brake Shoe

1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON

PL/SRT-4

BRAKES - BASE

5 - 17

BRAKE PADS/SHOES - FRONT (Continued)