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

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

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

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

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

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

⁄

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)

Content .. 44 45 46 47 ..