Dodge Neon / Neon SRT-4. Manual - part 35

CLEANING - DISC BRAKE SHOES

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

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

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.

Fig. 30 Supporting Caliper

1 - FLEX HOSE
2 - STRUT
3 - WIRE HANGER
4 - CALIPER ASSEMBLY

Fig. 31 Outboard Brake Shoe

1 - CALIPER FINGERS
2 - RETAINING CLIP

Fig. 32 Inboard Brake Shoe

1 - RETAINING CLIP
2 - INBOARD SHOE

5 - 22

BRAKES - BASE

PL/SRT-4

BRAKE PADS/SHOES - REAR DISC (Continued)

INSPECTION - DISC BRAKE SHOES

Visually inspect brake shoes (pads) for uneven lin-

ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors.

If a visual inspection does not adequately deter-

mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers.

Measure each brake shoe. The combined brake

shoe and its lining material thickness should be mea-
sured at its thinnest point.

For rear disc brake shoes, when a set of brake

shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced.

Replace both disc brake shoes (inboard and out-

board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.

If the brake shoe assemblies do not require

replacement, be sure to reinstall the brake shoes in
the original position they were removed from.

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, similar in
appearance, can be easily identified. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - DESCRIPTION
- DISC BRAKES (FRONT) - SRT-4)

NOTE: Perform Step 1 through Step 8 on each side
of vehicle to complete shoe set installation, then
proceed to Step 9.

(1) Completely retract the caliper piston back into

piston bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.

(2) Remove any protective paper from the noise

suppression gasket on both inner and outer brake
shoe assemblies (if equipped).

(3) Install the inboard brake shoe into the caliper

piston by firmly pressing the shoe in with the
thumbs (Fig. 32). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.

(4) Slide the outboard brake shoe onto the caliper

assembly (Fig. 31). Be sure the retaining clip is
squarely seated in the depressed areas on the caliper.

(5) Lubricate both adapter caliper slide abutments

with a liberal amount of Mopar

t Multipurpose Lubri-

cant, or an equivalent.

CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.

(6) Starting with the lower end, carefully lower the

caliper and brake shoes over the brake rotor and
catch the caliper’s bottom edge behind the caliper
slide abutment (Fig. 29). Rotate the top of the caliper
into mounting position on the adapter.

CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.

(7) Carefully install the caliper guide pin bolts

(Fig. 28), then tighten them to a torque of 22 N·m
(192 in. lbs.).

(8) 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.).

(9) Lower the vehicle.
(10) Pump the brake pedal to set the brake shoes

to the brake rotors, then check brake fluid level in
master cylinder reservoir. Adjust brake fluid level as
necessary.

(11) Road test the vehicle and make several stops

to wear off any foreign material on the brakes and to
seat the brake shoes.

BRAKE PADS/SHOES - REAR
DRUM

REMOVAL - DRUM BRAKE SHOES (REAR)

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

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

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove both rear tire and wheel assemblies

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

(3) Begin on one side of the vehicle.
(4) Remove the brake drum retaining clips (if

equipped) (Fig. 33).

(5) Remove the brake drum (Fig. 33).
(6) Remove the automatic adjustment lever-to-

brake shoe spring (Fig. 34).

(7) Remove the automatic adjustment lever (Fig.

35)from the brake shoe.

(8) Remove the hold down clips and pins attaching

the leading and trailing brake shoes to the brake
support plate (Fig. 36).

PL/SRT-4

BRAKES - BASE

5 - 23

BRAKE PADS/SHOES - REAR DISC (Continued)

(9) Remove the lower brake shoe-to-anchor plate

return spring (Fig. 37).

Fig. 33 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. 34 Automatic Adjustment Lever Spring

1 - ADJUSTMENT LEVER
2 - ADJUSTMENT LEVER TO BRAKE SHOE SPRING
3 - HUB/BEARING
4 - LEADING BRAKE SHOE
5 - AUTOMATIC ADJUSTER SCREW

Fig. 35 AUTOMATIC ADJUSTMENT LEVER

1 - AUTOMATIC ADJUSTMENT LEVER
2 - FRONT BRAKE SHOE ASSEMBLY

Fig. 36 Brake Shoe Hold Down Clips And Pins

1 - HOLD DOWN CLIP
2 - BRAKE SHOE
3 - SUPPORT PLATE
4 - PIN

5 - 24

BRAKES - BASE

PL/SRT-4

BRAKE PADS/SHOES - REAR DRUM (Continued)

(10) Remove the parking brake lever pin-to-brake

shoe retaining clip (Fig. 38).

(11) Remove the leading and trailing brake shoes,

upper return spring and automatic adjuster screw
from the brake support plate as an assembly (Fig.
39).

(12) Disassemble the shoes completely once on the

bench.

(13) Repeat the above procedure to the rear brakes

on the other side of the vehicle.

CLEANING - DRUM BRAKE SHOES

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

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

BY DRY

INSPECTION - DRUM BRAKE SHOES

Rear brake shoe lining should show contact across

the entire width of the lining and also from the heel
to the toe of the lining. Replace the shoes if noted
otherwise.

Fig. 37 Brake Shoe To Anchor Plate Return Spring

1 - ANCHOR PLATE
2 - LOWER BRAKE SHOE RETURN SPRING
3 - REAR BRAKE SHOE
4 - FRONT BRAKE SHOE
5 - BRAKE SUPPORT PLATE

Fig. 38 Parking Brake Lever Pin To Brake Shoe

Retaining Clip

1 - RETAINING CLIP
2 - PARK BRAKE LEVER PIN
3 - PARK BRAKE LEVER

Fig. 39 Brake Shoe Removal/Installation

1 - UPPER RETURN SPRING
2 - AUTOMATIC ADJUSTER SCREW
3 - TRAILING BRAKE SHOE
4 - WHEEL MOUNTING STUDS
5 - LEADING BRAKE SHOE
6 - BRAKE SUPPORT PLATE

PL/SRT-4

BRAKES - BASE

5 - 25

BRAKE PADS/SHOES - REAR DRUM (Continued)

Content .. 33 34 35 36 ..