Chrysler Neon 1995-1999 Repair Guide

Wheel Cylinders

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surface with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

See Figures 1, 2, 3 and 4

  1. Raise and safely support the vehicle. Remove the wheel and tire assembly.
  2.  
  3. If equipped, remove the brake drum-to-hub and bearing assembly retaining clips, then remove the brake drum.
  4.  
  5. Remove the brake shoes, as outlined earlier in this section. If the brake shoes are wet with grease or brake fluid, due to a leaky wheel cylinder, they must be replaced.
  6.  
  7. Disconnect the brake hose from the wheel cylinder.
  8.  



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Fig. Fig. 1: Disconnect the brake line from the back of the wheel cylinder (bleeder valve cap removed for access)

  1. Unfasten the wheel cylinder-to-backing plate retaining bolts, then remove the wheel cylinder from the plate.
  2.  



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Fig. Fig. 2: Unfasten the 2 wheel cylinder-to-backing plate bolts ...



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Fig. Fig. 3: ... then remove the wheel cylinder from the brake backing plate

To install:
  1. Install a small bead of silicone sealer around the wheel cylinder-to-backing plate mating surfaces.
  2.  



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Fig. Fig. 4: Apply a thin bead of silicone sealer around the wheel cylinder-to-backing plate mating surface

When installing the wheel cylinder on the backing plate, make sure the it is positioned squarely (horizontal) to the brake shoes.

  1. Position the wheel cylinder on the backing plate and install the attaching bolts. Tighten the bolts to 9.5 ft. lbs. (13 Nm).
  2.  
  3. Attach the brake line to the backing plate, then hand-start the tube nut fitting. Tighten the fitting to 12.5 ft. lbs. (17 Nm).
  4.  
  5. Install the rear brake shoe assemblies, as outlined earlier in this section.
  6.  
  7. Install the rear brake drum and retaining clips (if equipped).
  8.  
  9. Install the wheel and tire assembly. Adjust the brakes.
  10.  
  11. Carefully lower the vehicle, then properly bleed the brake system.
  12.  

OVERHAUL



See Figures 5 through 14

Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of attempting an overhaul.

If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system. Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill and bleed the system.

  1. Remove the wheel cylinder from the vehicle and place on a clean workbench.
  2.  
  3. First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.
  4.  



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Fig. Fig. 5: Remove the outer boots from the wheel cylinder

  1. Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in removing these components. If no compressed air is available, be VERY careful not to score the wheel cylinder bore when removing parts from it. Discard all components for which replacements were supplied in the rebuild kit.
  2.  



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Fig. Fig. 6: Compressed air can be used to remove the pistons and seals



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Fig. Fig. 7: Remove the pistons, cup seals and spring from the cylinder

  1. Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.
  2.  



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Fig. Fig. 8: Use brake fluid and a soft brush to clean the pistons ...



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Fig. Fig. 9: ... and the bore of the wheel cylinder


WARNING
Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These solvents will swell rubber components and quickly deteriorate them.

  1. Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in the cylinder bore.
  2.  
  3. Inspect the piston and replace it if it shows scratches.
  4.  



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Fig. Fig. 10: Once cleaned and inspected, the wheel cylinder is ready for assembly

  1. Lubricate the cylinder bore and seals using clean brake fluid.
  2.  
  3. Position the spring assembly.
  4.  
  5. Install the inner seals, then the pistons.
  6.  



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Fig. Fig. 11: Lubricate the cup seals with brake fluid



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Fig. Fig. 12: Install the spring, then the cup seals in the bore



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Fig. Fig. 13: Lightly lubricate the pistons, then install them

  1. Insert the new boots into the counterbores by hand. Do not lubricate the boots.
  2.  



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Fig. Fig. 14: The boots can now be installed over the wheel cylinder ends

  1. Install the wheel cylinder.
  2.  

 
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