Dodge Neon / Neon SRT-4. Manual - part 34

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.

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 front disc brake shoes, when a set of brake

shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.

Typically, if front shoes are worn out, both fronts

and rears need to be replaced. Make sure to check
rears. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REAR DISC -
INSPECTION)

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

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) Begin on one side of the vehicle.
(2) Completely retract the caliper piston back into

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

(3) Remove any protective paper from the noise

suppression gasket on both the inner and outer brake
shoes (if equipped).

(4) Install the inboard brake shoe into the caliper

piston by firmly pressing the shoe in with the
thumbs (Fig. 23). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.

(5) Slide the new outboard brake shoe onto the cal-

iper (Fig. 24).

(6) Lubricate both steering knuckle caliper slide

abutments with a liberal amount of Mopar

t Multi-

purpose Lubricant, or an equivalent.

CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.

(7) Install the disc brake caliper (with pads) on the

brake rotor and steering knuckle. The left side cali-
per is installed by first sliding the top of the caliper

Fig. 23 Installing Inboard Brake Shoe

1 - PISTON
2 - BRAKE SHOE
3 - CALIPER ASSEMBLY

5 - 18

BRAKES - BASE

PL/SRT-4

BRAKE PADS/SHOES - FRONT (Continued)

past the top caliper slide abutment on the steering
knuckle to hook the top edge of the caliper, then
pushing the lower end of the caliper into place
against the knuckle (Fig. 25). The right side caliper
is installed by first sliding the bottom edge of the cal-
iper past the lower caliper slide abutment on the
steering knuckle to hook the lower edge of the cali-
per, then pushing the top of the caliper into place
against the steering knuckle.

(8) Install the caliper guide pin bolts and tighten

them to a torque of 22 N·m (192 in. lbs.) (Fig. 19).

(9) 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.).

(10) Repeat the above procedure to the front

brakes on the other side of the vehicle.

(11) Lower the vehicle.
(12) 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.

(13) Road test the vehicle and make several stops

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

BRAKE PADS/SHOES - FRONT -
SRT-4

REMOVAL

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)

NOTE: Perform Step 2 through Step 5 on each side
of the vehicle to complete shoe set removal.

(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts

(Fig. 26).

(4) Remove the disc brake caliper from the disc

brake adapter and hang out of the way using wire or
a bungee cord. Use care not to overextend the brake
hose when doing this.

Fig. 24 Installing Outboard Brake Shoe

1 - BRAKE SHOE ASSEMBLY
2 - BRAKE CALIPER

Fig. 25 Installing Left Caliper

1 - SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT OF
STEERING KNUCKLE AS SHOWN
2 - BRAKING DISC
3 - DISC BRAKE CALIPER
4 - STEERING KNUCKLE BRAKE ABUTMENT

Fig. 26 Brake Caliper Mounting (Typical)

1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS

PL/SRT-4

BRAKES - BASE

5 - 19

BRAKE PADS/SHOES - FRONT (Continued)

(5) Remove the brake shoes from the disc brake

caliper adapter (Fig. 27).

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

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 front disc brake shoes, when a set of brake

shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.

Typically, if front shoes are worn out, both fronts

and rears need to be replaced. Make sure to check
rears. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REAR DISC -
INSPECTION)

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 remove from.

INSTALLATION

NOTE: Perform Step 1 through Step 5 on each side
of the vehicle to complete shoe set installation,
then proceed to Step 6.

NOTE: Inboard brake shoes are not identical side-
to-side. This is due to placement of the audible
wear indicator on the end of each inboard shoe.
Make sure that the audible wear indicators are
placed toward the top when the inboard shoes are
installed on each side of the vehicle.

(1) Place the brake shoes in the abutment shims

clipped into the disc brake caliper adapter as shown
(Fig. 27). Place the shoe with the wear indicator
attached on the inboard side.

(2) Completely retract the caliper piston back into

the bore of the caliper.

CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.

(3) Install the disc brake caliper over the brake

shoes on the brake caliper adapter. Make sure the

Fig. 27 Brake Shoes Mounted In Adapter

1 - SPRINGS
2 - INBOARD SHOE
3 - OUTBOARD SHOE
4 - DISC BRAKE ADAPTER
5 - ABUTMENT SHIMS
6 - BRAKE ROTOR

5 - 20

BRAKES - BASE

PL/SRT-4

BRAKE PADS/SHOES - FRONT - SRT-4 (Continued)

springs on the shoes do not get caught in the hole
formed into the center of the caliper housing.

(4) Align the caliper guide pin bolt holes with the

guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
26).

(5) Install the tire and wheel assembly. Tighten

the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).

(6) Lower the vehicle.
(7) Pump the brake pedal several times before

moving the vehicle to set the shoes to the brake
rotor.

(8) Check and adjust the brake fluid level as nec-

essary.

(9) 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
DISC

REMOVAL

NOTE: Before proceeding, (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 vehicle (Refer to 22 - TIRES/WHEELS -
REMOVAL).

NOTE: Perform Step 3 through Step 7 on each side
of vehicle to complete shoe set removal.

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.

(3) Remove the two caliper guide pin bolts (Fig.

28).

(4) Remove the caliper assembly from the brake

adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 29).

(5) Hang the brake caliper from rear strut using

wire or cord to prevent the weight of the caliper from
damaging the brake hose (Fig. 30).

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

per by prying the brake shoe retaining clip over the
raised area on the caliper. Then slide the brake shoe
down and off of the brake caliper (Fig. 31).

(7) Pull the inboard brake shoe away from caliper

piston until the retaining clip is free from the cavity
in the piston (Fig. 32).

Fig. 28 Caliper And Rotor Mounting

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

Fig. 29 Caliper Removal/Installation

1 - BRAKING DISC
2 - CALIPER ADAPTER
3 - CALIPER
4 - LOWER MACHINED ADAPTER ABUTMENT

PL/SRT-4

BRAKES - BASE

5 - 21

BRAKE PADS/SHOES - FRONT - SRT-4 (Continued)

Content .. 32 33 34 35 ..