Dodge Neon / Neon SRT-4. Manual - part 48

STANDARD PROCEDURE - AUTOMATIC
ADJUSTER UNLOCKING

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.

WARNING:

WHEN

REPAIRS

THE

PARKING

BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY.

NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster locking pin or pin punch.

(1) Be sure the rear parking brake cables are both

properly installed in the equalizer.

(2) Keeping your hands clear of the automatic

adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 140), then
quickly remove it from the parking brake lever mech-
anism. This will allow the park brake lever mecha-
nism to automatically adjust the parking brake
cables.

(3) Cycle the parking brake lever once to position

the parking brake cables, then return the parking
brake lever its released position.

(4) Check the rear wheels of the vehicle. They

should rotate freely without dragging with the lever
in its released position.

(5) Fully apply the parking brake lever.
(6) Install the center console and its mounting

screws.

(7) Remove the blocks from the tire and wheels.

CABLES - PARKING BRAKE

REMOVAL

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

The procedure below applies to either of the two

rear parking brake cables.

(1) Block the tire and wheels so the vehicle does

not move once the vehicle parking brake lever is
released.

(2) Fully apply the parking brake lever, then shift

the transmission into neutral.

(3) Remove the screws attaching the center con-

sole, then remove the center console.

(4) Lower the parking brake lever handle to the

released position.

(5) Grasp the parking brake lever output cable by

hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 149). This
will lock the parking brake automatic adjustment
mechanism in place and take tension off the parking
brake cables.

(6) Remove both rear parking brake cables from

the parking brake cable equalizer (Fig. 150).

(7) Remove the rear seat cushion from the vehicle.
(8) Fold the rear carpeting forward to expose the

parking brake cables at the end of the rear floor.

(9) Install the box end of a

⁄

inch wrench over the

parking brake cable retainer (Fig. 141). Push the
wrench onto the retainer until the retainer fingers
are collapsed. From under the carpeting, grasp the
parking brake cable housing and pull cable straight
out of the bracket attached to the floor.

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

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(11) Remove the rear tire and wheel assembly

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

Fig. 141 Compressing Cable Retainer

1 - CARPET ROLLED FORWARD
2 - WRENCH
3 - RIGHT REAR CABLE
4 - REAR PARKING BRAKE CABLES
5 - LEFT REAR CABLE

5 - 74

BRAKES - BASE

PL/SRT-4

PARKING BRAKE (Continued)

(12) On vehicles equipped with rear drum brakes,

remove the brake drum. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL).

(13) On vehicles equipped with rear disc brakes:
• Remove the disc brake caliper guide pin bolts,

then the caliper from disc brake adapter (Fig. 142).

• Hang the caliper out of the way using a wire

hanger or cord.

• Remove the brake rotor from the rear hub and

bearing.

(14) Remove the dust cap from the rear hub and

bearing.

(15) Remove the hub and bearing retaining nut

from the knuckle spindle, then remove the hub and
bearing (Fig. 142).

(16) On vehicles equipped with rear disc brakes,

remove the upper return spring, both shoe hold-down
clips, then spread the rear parking brake shoes apart
at the top enough to clear the shoe anchor and
remove the parking brake shoes as an assembly from
the disc brake adapter (Fig. 143).

(17) To remove the rear parking brake cable from

the brake support plate on vehicles equipped with
rear drum brakes:

• Remove the parking brake cable from the park-

ing brake actuating lever (Fig. 144).

• Remove the actuating spring between the brake

shoe adjustment lever and the brake shoe (Fig. 145).

• Remove the parking brake cable from the rear

brake support plate. The parking brake cable can be
removed from brake support plate using a

⁄

inch

box wrench to compress the locking fingers on the
parking brake cable retainer (Fig. 146).

(18) To remove the rear parking brake cable from

the disc brake adapter on vehicles equipped with
rear disc brakes:

• Remove the parking brake actuating lever from

the parking brake cable (Fig. 147).

• Remove the parking brake cable from the rear

disc brake adapter. The parking brake cable can be
removed from the disc brake adapter using a

⁄

inch

Fig. 142 Rear Disc Brakes

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. 143 Parking Brake Shoes

1 - UPPER RETURN SPRING
2 - SHOE HOLD DOWN CLIPS
3 - ADJUSTER
4 - LOWER REAR SPRING
5 - DISC BRAKE ADAPTER

Fig. 144 Actuator Lever

1 - PARK BRAKE ACTUATING LEVER
2 - PARK BRAKE CABLE
3 - BRAKE SHOE ASSEMBLIES
4 - REAR SPINDLE

PL/SRT-4

BRAKES - BASE

5 - 75

CABLES - PARKING BRAKE (Continued)

offset box wrench to compress the locking fingers on
the parking brake cable retainer (Fig. 148).

(19) Remove the nuts, then the parking brake

cable routing bracket from the tension strut mount-
ing bolts.

(20) Remove the parking brake cable and sealing

grommet from floor pan of the vehicle.

INSTALLATION

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

The procedure below applies to either of the two

rear parking brake cables.

(1) From underneath push the parking brake cable

through the hole in the floor pan of the vehicle mak-
ing sure the cable sealing grommet is installed in the
floor pan as far as possible to insure a good seal.

(2) Attach the parking brake cable routing bracket

to the tension strut mounting bolts. Install and
tighten the mounting nuts to a torque of 28 N·m (250
in. lbs.).

(3) Install the parking brake cable into the brake

support plate or the rear disc brake adapter. Be sure
the

locking

fingers

the

cable

retainer

are

expanded once the cable is pushed all the way into

Fig. 145 Actuating Spring

1 - BRAKE SHOE ADJUSTMENT LEVER
2 - ADJUSTMENT LEVER ACTUATING SPRING
3 - PARK BRAKE CABLE

Fig. 146 Parking Brake Cable Removal

1 - PARK BRAKE CABLE
2 - 1/2

WRENCH

3 - REAR BRAKE SUPPORT PLATE
4 - PARK BRAKE CABLE RETAINER

Fig. 147 Parking Brake Actuator Lever

1 - SHOE ACTUATOR LEVER
2 - SHIELD MOUNTING SCREWS
3 - REAR PARKING BRAKE CABLE

Fig. 148 Parking Brake Cable Removal

1 - CABLE RETAINER
2 - OFFSET BOX WRENCH
3 - PARKING BRAKE CABLE

5 - 76

BRAKES - BASE

PL/SRT-4

CABLES - PARKING BRAKE (Continued)

the support plate or brake adapter hole to ensure the
cable is securely held in place.

(4) On vehicles equipped with rear drum brakes:
• Install the parking brake cable on the parking

brake cable actuating lever (Fig. 144).

• Install the actuating spring to the brake shoe

and the brake adjustment lever (Fig. 145).

(5) On vehicles equipped with rear disc brakes:
• Install the parking brake shoes actuator lever on

the parking brake cable (Fig. 147).

• Install the parking brake shoe assemblies on the

disc brake adapter (Fig. 143).

(6) Install the hub and bearing on the rear spin-

dle. Install a new hub and bearing retaining nut.
Tighten the retaining nut to a torque of 217 N·m
(160 ft. lbs.).

(7) Install the hub and bearing dust cap.
(8) On drum brake equipped vehicles, install the

rear brake drum.

(9) On vehicles equipped with rear disc brakes,

install the brake rotor, then the disc brake caliper
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION) (Fig. 142). Install the
two caliper guide pin bolts, then tighten them to a
torque of 22 N·m (192 in. lbs.).

(10) Install the rear tire and wheel assembly

(Refer to 22 - TIRES/WHEELS - INSTALLATION).
Tighten all wheel nuts to a torque of 135 N·m (100 ft.
lbs.).

(11) Lower the vehicle.
(12) Ensure that the seal grommet on the cable

that was installed from underneath is fully seated
into the floor pan.

(13) Route the parking brake cable under the car-

peting, up to parking brake cable retaining bracket
on floor pan. Install the parking brake cable through
the retaining bracket. Push the cable in until the
locking fingers on the cable retainer lock the cable
into place.

(14) Install the rear parking brake cables into the

equalizer on the parking brake lever output cable
(Fig. 150).

(15) Ensure that the parking brake cables are cor-

rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.

NOTE: The parking brake lever can be in any posi-
tion when releasing the automatic adjuster.

(16) Keeping your hands clear of the automatic

adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 149), then
quickly remove it from the parking brake lever mech-
anism. This will allow the park brake lever mecha-
nism to automatically adjust the parking brake
cables.

(17) Cycle the parking brake lever once to position

the parking brake cables, then return the parking
brake lever its released position.

(18) Check the rear wheels of the vehicle. They

should rotate freely without dragging with the lever
in its released position.

(19) Reposition the rear carpeting into place.
(20) Install the rear seat cushion. Be sure the seat

cushion is fully installed in the retainers on the floor
pan of the vehicle.

(21) Fully apply the parking brake lever.
(22) Install the center console and its mounting

screws.

(23) Remove the blocks from the tires and wheels.

LEVER - PARKING BRAKE

REMOVAL

WARNING:

WHEN

REPAIRS

THE

PARKING

BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER

ADJUSTMENT

MECHANISM

CAN

LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.

(1) Block the tire and wheels so the vehicle does

not move once the vehicle parking brake lever is
released.

(2) Fully apply the parking brake lever, then shift

the transmission into neutral.

(3) Remove the screws attaching the center con-

sole, then remove the center console.

(4) Lower the parking brake lever handle to the

released position.

(5) Grasp the parking brake lever output cable by

PL/SRT-4

BRAKES - BASE

5 - 77

CABLES - PARKING BRAKE (Continued)

Content .. 46 47 48 49 ..