Dodge Neon / Neon SRT-4. Manual — part 32
BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the left
side of the brake fluid reservoir on the master cylin-
der (Fig. 3). It is clipped into the reservoir. It can be
removed from the reservoir and replaced if necessary.
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder reservoir has
dropped below an acceptable level.
As the fluid drops below the designed level, the
fluid level switch closes and grounds the red BRAKE
warning indicator circuit. This turns on the red
BRAKE warning indicator. At this time, the master
cylinder brake fluid reservoir must be checked and
filled to the full mark with DOT 3 brake fluid. Check
the entire brake hydraulic system for evidence of a
leak.
CAUTION: An abnormal loss of brake fluid in the
master cylinder fluid reservoir could be caused by a
leak in the hydraulic system. The entire brake
hydraulic system should be checked for evidence
of a leak.
REMOVAL
NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).
(1) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 3).
(2) Push together the retaining tabs holding the
brake fluid level switch in place in the brake fluid
reservoir (Fig. 4).
(3) Pull the brake fluid level switch out the other
side of the reservoir.
INSTALLATION
NOTE: Before proceeding with this procedure,
(Refer to 5 - BRAKES - WARNING).
(1) Align the brake fluid level switch with its
mounting hole on the left side of the master cylinder
brake fluid reservoir. Push the switch into the fluid
reservoir
until
the
switch
retaining
tabs
are
expanded on the other side of the reservoir, locking it
in place (Fig. 4).
(2) Connect the brake fluid level switch wiring
connector (Fig. 3).
Fig. 3 Master Cylinder and Power Brake Booster
1 - POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 - POWER BRAKE BOOSTER
3 - BRAKE FLUID LEVEL SWITCH
4 - MASTER CYLINDER
Fig. 4 Master Cylinder Reservoir
1 - BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 - RESERVOIR RETAINING PINS
3 - SEAL
5 - 10
BRAKES - BASE
PL/SRT-4
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
The front disc brakes consist of the following com-
ponents (Fig. 5):
• Brake caliper - single-piston, floating type
• Brake shoes and linings
• Brake rotor
The caliper is a one-piece casting with the inboard
side containing a single piston cylinder bore (Fig. 6).
The front disc brake caliper piston, is manufac-
tured from a phenolic compound. The outside diame-
ter of the caliper piston is 54 mm.
The caliper is mounted to the steering knuckle
using bushings, sleeves and two guide pin bolts (Fig.
6). The guide pin bolts thread directly into bosses on
the steering knuckle.
Two machined abutments on the steering knuckle
position the caliper. The guide pin bolts, sleeves, and
bushings control the side-to-side movement of the
caliper. All of the front brake force generated during
braking of the vehicle is taken up directly by the
steering knuckles of the vehicle.
There are two brake shoes mounted to each caliper,
one inboard and one outboard (Fig. 6). When brake
Fig. 6 Front Disc Brake Caliper
1 - CALIPER GUIDE PIN BOLT
2 - SLEEVE
3 - BUSHING
4 - CALIPER
5 - PISTON SEAL
6 - PISTON
7 - DUST SEAL
8 - WEAR INDICATOR
9 - ANTI-RATTLE CLIP
10 - BRAKE SHOE
11 - BRAKE SHOE
12 - ANTI-RATTLE CLIP
13 - BUSHING
14 - SLEEVE
15 - CALIPER GUIDE PIN BOLT
16 - CAP
17 - BLEEDER SCREW
Fig. 5 Front Disc Brakes
1 - STEERING KNUCKLE
2 - BRAKE PADS AND LININGS
3 - BRAKE ROTOR
4 - DRIVING HUB
5 - CALIPER ASSEMBLY
PL/SRT-4
BRAKES - BASE
5 - 11
shoes are replaced, only brake shoes meeting the
original equipment manufacturer (OEM) formulation
(such as Mopar
t replacement parts) should be used.
The brake shoe linings contact the brake rotor.
Each front brake rotor is vented to help cool it during
and after brake applications. It is mounted on the
studs of the front wheel bearing hub.
DESCRIPTION - DISC BRAKES (FRONT) -
SRT-4
This vehicle is equipped with a performance brake
system that features heavy duty wheel brake compo-
nents. The sales code for this system is BR3. Each
front disc brake assembly consists of the following
components (Fig. 7):
• Caliper - single-piston, floating type
• Caliper adapter
• Shoe and lining assemblies (Pads)
• Rotor
The BR3 brake caliper can be easily identified.
Each BR3 brake caliper is painted red and is marked
“Turbo” referring to the engine package the vehicle is
equipped with. The caliper is a one-piece casting with
the inboard side containing a single piston cylinder
bore. The front disc brake caliper piston, is manufac-
tured from a phenolic compound. The outside diame-
ter of the caliper piston is 57 mm.
A square-cut rubber piston seal is located in a
machined groove in the caliper cylinder bore. This
seal provides a hydraulic seal between the piston and
the cylinder wall (Fig. 8).
A rubber dust boot is installed in a groove in cyl-
inder bore opening and in a groove in the piston (Fig.
9). The boot prevents contamination in the bore area.
The BR3 caliper is mounted to the caliper adapter
using two guide pin bolts. These bolts thread into
two guide pins, slid into the adapter (Fig. 10). The
pins are lubricated and have boots to seal them in
place in the adapter.
The caliper adapter is fastened to the steering
knuckle using two bolts (Fig. 11).
The machined abutments on the adapter position
the brake shoes and caliper. There are two brake
shoes, sometimes referred to as pads, per disc brake.
One shoe is placed on each side of the brake rotor
(Fig. 12). Two abutment shims (upper and lower) ride
between the shoes and adapter. The shoes have
springs permanently attached to them to help main-
tain a distance between the shoes and the caliper.
When brake shoes are replaced, only brake shoes
meeting the original equipment manufacturer (OEM)
Fig. 7 Front Disc Brakes
1 - BRAKE ROTOR
2 - ABUTMENT SHIMS
3 - DISC BRAKE ADAPTER
4 - CALIPER
5 - BRAKE SHOES (PADS)
Fig. 8 Piston Seal Function
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
Fig. 9 Piston Boot Installation
5 - 12
BRAKES - BASE
PL/SRT-4
HYDRAULIC/MECHANICAL (Continued)
formulation (such as Mopar
t replacement parts)
should be used.
Front disc brakes are equipped with audible wear
indicators on the inboard brake shoes.
Each front brake rotor is vented to help cool it dur-
ing and after brake applications. It is mounted on
the studs of the front wheel bearing hub. The BR3
rotor can be easily identified by a recessed machined
area near the hub center that is not present on a
standard brake rotor (Fig. 13).
NOTE: Special care should be taken to assure that
the correct caliper is used only with the correct
rotor.
Fig. 13 Front Brake Rotor Comparison
1 - STANDARD PL BRAKE ROTOR
2 - STANDARD ROTOR THICKNESS 21.87-22.13 MM
3 - PERFORMANCE ROTOR THICKNESS 27.91-28.10 MM
4 - PERFORMANCE BRAKE ROTOR
5 - INDENTIFYING MACHINED AREA
Fig. 10 Adapter, Boots And Pins
1 - PINS
2 - BOOTS
Fig. 11 Adapter Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
Fig. 12 Brake Shoes Mounted In Adapter
1 - SPRINGS
2 - INBOARD SHOE
3 - OUTBOARD SHOE
4 - DISC BRAKE ADAPTER
5 - ABUTMENT SHIMS
6 - BRAKE ROTOR
PL/SRT-4
BRAKES - BASE
5 - 13
HYDRAULIC/MECHANICAL (Continued)
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