Chrysler Neon 1995-1999 Repair Guide

Bleeding the Brake System

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For vehicles equipped with the Anti-Lock Brake System (ABS), please refer to the bleeding procedure in that information.

The purpose of bleeding the brakes is to expel air trapped in the hydraulic system. The system must be bled whenever the pedal feels spongy, indicating that compressible air has entered the system. It must also be bled whenever the system has been opened or repaired. If you are not using a pressure bleeder, you will need a helper for this job.


CAUTION
Never reuse brake fluid which has been bled from the brake system.

PRESSURE BLEEDING



When bleeding the brakes, may be trapped in the brake lines or valves far upstream, as much as 10 feet from the bleeder screw. Therefore, it is very important to have a fast flow of a large volume of brake fluid when bleeding the brakes to make sure all of the air is expelled from the system.

The following wheel sequence should be used to be sure all of the air is removed from the system:



Left rear wheel
 
Right front wheel
 
Right rear wheel
 
Left front wheel
 

  1. You should use bleeder tank tool C-3496-B or equivalent, with the required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. Make sure to follow the manufacturer's directions for using a pressure bleeder.
  2.  
  3. Attach a clear plastic hose to the bleeder screw located at the right rear wheel, then plate the hose into a clean jar that has enough fresh brake fluid to submerge the end of the hose.
  4.  
  5. Open the bleeder screw at least one full turn or more to get a steady stream of fluid.
  6.  
  7. After about 4-8 oz. of fluid has been bled through the brake system and an air-free flow is maintained in the hose and jar, close the bleeder screw.
  8.  
  9. Repeat the procedure at all the other remaining bleeder screws. Then, check the pedal for travel. If pedal travel is excessive or has not improved, enough fluid has not passed through the system to expel all of the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to re-enter the brake system through the master cylinder reservoir.
  10.  
  11. Once the bleeding procedure is complete, remove the pressure bleeding equipment from the master cylinder.
  12.  

MANUAL BLEEDING



See Figures 1 and 2

Proper manual bleeding of the hydraulic brake system will require the air of a helper.

The following wheel sequence should be used to be sure all of the air is removed from the system:



Left rear wheel
 
Right front wheel
 
Right rear wheel
 
Left front wheel
 

  1. Attach a clear plastic hose to the bleeder screw located at the right rear wheel, then plate the hose into a clean jar that has enough fresh brake fluid to submerge the end of the hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: The bleeder valve has a rubber cap on it that must be removed in order to bleed the brakes



Click image to see an enlarged view

Fig. Fig. 2: Attach a hose to the bleeder valve, submerge the other end in clean brake fluid, then open the valve



Click image to see an enlarged view

Fig. Fig. 3: Bleeding the front disc brake calipers

  1. Have an assistant pump the brake pedal 3-4 times, and hold it down before the bleeder screw is opened.
  2.  
  3. Open the bleeder screw at least one full turn. When the bleeder screw opens, the brake pedal will drop.
  4.  
  5. Close the bleeder screw. Release the brake pedal only AFTER the bleeder screw is closed.
  6.  
  7. Repeat the procedure 4 or 5 times at each bleeder screw. Then check the pedal for travel. If the pedal travel is not excessive, or has not been improved, enough fluid has not passed through the system to expel all of the trapped air. Make sure to watch the fluid level in the master cylinder reservoir. It must stay at the proper level so air will not reenter the brake system.
  8.  
  9. Test drive the vehicle to be sure the brakes are operating correctly and that the pedal is solid.
  10.  

MASTER CYLINDER BLEEDING



See Figure 4

  1. Remove the master cylinder from the vehicle and clamp in a soft jawed vise. Attach suitable bleeding tubes (tool 6802 or equivalent) to the master cylinder. Position so the outlets of the bleeding tubes will be below the surface of the brake fluid when the reservoir is filled to the proper level.
  2.  
  3. Fill the master cylinder reservoir with DOT 3 brake fluid from a fresh, sealed container.
  4.  
  5. Use a wooden dowel to depress the pushrod slowly, then allow the pistons to return to their released position. You should repeat this several times until all air bubbles are expelled.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: With the special bleeding tubes attached, depress the pushrod slowly with a wooden dowel

  1. Remove the bleeding tubes from the master cylinder outlet ports, then plug the ports and install the cap on the master cylinder reservoir.
  2.  
  3. Remove the master cylinder from the vise and install in the vehicle.
  4.  

 
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