Dodge Neon / Neon SRT-4. Manual — part 46
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 127) or stamped into the hat section.
Minimum
thickness
specifications
can
also
be
found in the specification table in this section.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTOR - SPECIFICATIONS)
Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before lathe installation, verify the brake rotor
face and the hub adapters are free of any chips, rust,
or contamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer’s operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required. Specifi-
cations for brake rotor machining can be found in
this
sections
specification
table.
(Refer
to
5
-
BRAKES/HYDRAULIC/MECHANICAL/ROTOR
-
SPECIFICATIONS)
REMOVAL
REMOVAL - FRONT
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.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
(3) Remove the front disc brake caliper assembly
from the brake rotor and store it out of the way.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(4) Remove the clips retaining the brake rotor (Fig.
19).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
REMOVAL - FRONT - SRT-4
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) Slide the caliper outward in an effort to retract
the caliper piston into its bore.
(4) Remove the two bolts securing disc brake cali-
per adapter to the steering knuckle (Fig. 128).
(5) Remove the disc brake caliper and adapter
from the knuckle as an assembly. Hang the assembly
out of the way using wire or a bungee cord. Use care
not to overextend the brake hose when doing this.
(6) Remove the clips retaining the brake rotor to
the wheel studs.
(7) Remove the brake rotor.
Fig. 127 Minimum Brake Rotor Thickness (Typical)
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
Fig. 128 Caliper/Adapter Mounting
1 - STEERING KNUCKLE
2 - DISC BRAKE CALIPER
3 - DISC BRAKE CALIPER ADAPTER
4 - BRAKE ROTOR
5 - 66
BRAKES - BASE
PL/SRT-4
ROTOR (Continued)
REMOVAL - REAR
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 rear tire and wheel assembly.(Re-
fer to 22 - TIRES/WHEELS - REMOVAL)
(3) Remove the rear disc brake caliper assembly
from the brake rotor and store it out of the way.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(4) Remove any clips retaining the brake rotor
(Fig. 28).
(5) Remove the brake rotor by pulling it straight
off the wheel mounting studs.
INSTALLATION
INSTALLATION - FRONT
(1) Install the brake rotor over the wheel mount-
ing studs and onto the hub (Fig. 19).
(2) Install the front disc brake caliper. It may be
necessary to retract the brake caliper piston back
into the caliper to fit the shoes onto the rotor. (Refer
to
5
-
BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSTALLATION).
(3) 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.).
(4) Lower the vehicle.
(5) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
INSTALLATION - FRONT - SRT-4
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, similar in
appearance, can be easily identified (Fig. 118).(Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
DESCRIPTION)
NOTE: Inspect disc brake shoes before installation.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSPECTION)
(1) Install the brake rotor over the studs on the
hub.
(2) Install the disc brake caliper and adapter
assembly over the brake rotor.
(3) Install the mounting bolts securing the caliper
adapter to the steering knuckle (Fig. 128). Tighten
the bolts to a torque of 104 N·m (77 ft. lbs.).
(4) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(5) Lower the vehicle.
(6) Pump the brake pedal several times before
moving the vehicle to set the shoes to the brake
rotor.
(7) Road test the vehicle and make several stops to
seat the brake shoes to the rotor.
INSTALLATION - REAR
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, similar in
appearance, can be easily identified (Fig. 119).(Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
DESCRIPTION)
NOTE: Inspect disc brake shoes and parking brake
shoes before installation. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE
PADS/SHOES
-
INSPECTION)
(1) Install the rear brake rotor over the wheel
mounting studs and onto the hub (Fig. 28).
(2) Install rear disc brake caliper and shoes. (Refer
to
5
-
BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSTALLATION)
(3) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(4) Adjust the parking brake shoes as necessary.
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS)
(5) Lower the vehicle.
(6) Pump the brake pedal before moving the vehi-
cle to set the brake shoes to the brake rotor.
PL/SRT-4
BRAKES - BASE
5 - 67
ROTOR (Continued)
SPECIFICATIONS
BRAKE ROTOR LIMITS/SPECIFICATIONS
NOTE: When refacing a rotor, the required TIR
(Total Indicator Reading) and thickness variation
limits MUST BE MAINTAINED.
Braking Rotor
Rotor Thickness
Minimum Rotor
Thickness
Rotor Thickness
Variation
Rotor Runout*
Front Rotor
21.87–22.13 mm
0.861-0.871 in.
20.4 mm
0.803 in.
0.013 mm
0.0005 in.
0.13 mm
0.005 in.
Rear Rotor
8.75–9.25 mm
0.344 -0.364 in.
7.25 mm
0.285 in.
0.013 mm
0.0005 in.
0.13 mm
0.005 in.
* TIR Total Indicator Reading (Measured On Vehicle)
BRAKE ROTOR LIMITS/SPECIFICATIONS -
SRT-4
NOTE: When refacing a rotor, the required TIR
(Total Indicator Reading) and thickness variation
limits MUST BE MAINTAINED.
BR3 SALES CODE
Braking Rotor
Rotor Thickness
Minimum Rotor
Thickness
Rotor Thickness
Variation
Rotor Runout*
Front Rotor
27.91–28.10 mm
1.099–1.106 in.
26.40 mm
1.039 in.
0.010 mm
0.0004 in.
0.13 mm
0.005 in.
Rear Rotor
11.75–12.25 mm
0.463–0.482 in.
10.25 mm
0.404 in.
0.013 mm
0.0005 in.
0.13 mm
0.005 in.
* TIR Total Indicator Reading (Measured On Vehicle)
SUPPORT PLATE - DRUM
BRAKE
REMOVAL
NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).
(1) Using a brake pedal holding tool as shown (Fig.
129), depress the brake pedal past its first one inch
of travel and hold 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.
(2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove the rear tire and wheel assembly from
the
vehicle
(Refer
to
22
-
TIRES/WHEELS
-
REMOVAL).
(4) Disconnect the rear brake flex hose from the
wheel cylinder (Fig. 130).
(5) Remove the rear brake drum (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DRUM
-
REMOVAL).
(6) Remove the dust cap (Fig. 131) from the rear
hub and bearing.
5 - 68
BRAKES - BASE
PL/SRT-4
ROTOR (Continued)
(7) Remove the nut holding the rear hub and bear-
ing to the spindle (Fig. 132). Remove the hub and
bearing from the spindle.
(8) Remove the rear brake shoes from the brake
support plate. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - REMOVAL).
(9) Remove the parking brake actuator lever from
the parking brake cable.
(10) Position a
1
⁄
2
inch wrench over the retainer
fingers on the end of the parking brake cable (Fig.
133). Compress the cable housing retaining fingers
with the wrench, then pull the cable housing out of
the support plate. Remove the wrench as the parking
brake cable retainer is freed from the mounting hole
in the brake support plate.
(11) Remove the 4 brake support plate mounting
bolts and washers. Separate brake support plate
from rear suspension knuckle.
(12) Remove the brake wheel cylinder attaching
bolts.
(13) Remove the brake wheel cylinder from the
brake support plate.
Fig. 129 Brake Pedal Holding Tool
1 - CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 - THROTTLE PEDAL
3 - BRAKE PEDAL HOLDING TOOL
4 - STEERING WHEEL
5 - DRIVER’S SEAT
6 - BRAKE PEDAL
Fig. 130 Brake Flex Hose At Wheel Cylinder
1 - BRAKE SUPPORT PLATE
2 - WHEEL CYLINDER ATTACHING BOLTS
3 - REAR BRAKE FLEX HOSE TUBE
4 - WHEEL CYLINDER ASSEMBLY
Fig. 131 Hub And Bearing Dust Cap
1 - HUB/BEARING ASSEMBLY
2 - DUST CAP
Fig. 132 Rear Hub And Bearing Retaining Nut
1 - RETAINING NUT
2 - SPINDLE
3 - HUB/BEARING ASSEMBLY
PL/SRT-4
BRAKES - BASE
5 - 69
SUPPORT PLATE - DRUM BRAKE (Continued)
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