Chrysler Neon 1995-1999 Repair Guide

Cables

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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 through 14


WARNING
Remove only one rear parking brake cable from the rear brakes at a time. If you attempt to remove both cables at the same time, it will be difficult to connect the cables to the equalizer or parking brake lever at the rear wheel brakes.

  1. From inside the passenger compartment, unfasten the screws securing the rear of the console to the floor pan of the vehicle.
  2.  
  3. Remove the 2 screws found in the cup holders attaching the front of the center console to the console bracket.
  4.  
  5. Raise the parking brake lever as high as it will go for the clearance necessary to remove the console. Remove the center console from the vehicle.
  6.  

When repairs to the parking brake hand lever or cables is required, the auto adjuster must be reloaded and locked out.

  1. Lower the parking brake lever handle.
  2.  
  3. Grasp the parking brake lever output cable by hand, then pull it rearward. Keep pulling on the cable until a 3 / 16 in. (5mm) drill bit can be inserted into the handle and sector gear of the parking brake mechanism. This will lock the parking brake mechanism and take tension off the parking brake cables.
  4.  



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Fig. Fig. 1: Place a drill bit in the handle and sector gear to lock the parking brake mechanism and tension off the cables

  1. Remove the rear parking brake cables from the parking brake cable equalizer.
  2.  



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Fig. Fig. 2: Detach the parking brake cables from the equalizer

  1. Remove the rear seat cushion from the vehicle.
  2.  
  3. Use a prytool to carefully remove the scuff plates from the right and left door sills. The scuff plates are attached to the door sills using clips on the bottom of the scuff plates.
  4.  
  5. Fold the rear carpeting forward to reveal the parking brake cables.
  6.  
  7. Install the box end of a 1 / 2 in. wrench over the parking brake cable retainer as shown in the accompanying illustration. Doing this will compress the tabs on the parking brake cable retainers, letting the cable be removed from the console bracket. From under the carpet, grab the parking brake cable housing and pull the cable straight out of the console bracket.
  8.  



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Fig. Fig. 3: You must compress the tabs on the cable retainers in order to remove the cable from the console bracket

  1. Raise and safely support the vehicle, then remove the rear wheel and tire assembly.
  2.  
  3. If equipped with drum brakes, remove the brake drum from the hub and bearing assembly.
  4.  
  5. If equipped with disc brakes, remove caliper and rotor.
  6.  
  7. Remove the dust cap from the rear hub and bearing assembly using a suitable pair of pliers or equivalent as shown in the accompanying illustration.
  8.  
  9. Remove the hub and bearing retaining nut from the spindle, then remove the hub and bearing assembly. Discard the retaining nut and replace with a new one during installation.
  10.  
  11. If equipped with drum brakes, remove the parking brake cable from the parking brake actuating lever. Then, remove the actuating spring from between the brake shoe adjustment lever and the brake shoe assembly.
  12.  



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Fig. Fig. 4: For rear drum brakes, remove the parking brake cable from the actuating lever ...



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Fig. Fig. 5: ... then remove the actuating spring between the brake shoe adjustment lever and the brake shoe assembly

  1. If equipped with rear disc brakes, remove the brake shoe assemblies from the rear disc brake adapter. Then, remove the parking brake actuating lever from the parking brake cable.
  2.  



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Fig. Fig. 6: For rear disc brakes, remove the brake shoe assemblies from the adapter ...



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Fig. Fig. 7: ... then remove the parking brake actuating lever from the parking brake cable

  1. If equipped with rear drum brakes, remove the parking brake cable from the rear brake support plate. You can remove the cable from the support plate by using a 1 / 2 in. wrench to compress the locking tabs on the parking brake cable retainer.
  2.  



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Fig. Fig. 8: For rear drum brakes, use a wrench to compress the locking tabs, then remove the parking brake cable from the support plate



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Fig. Fig. 9: You can also use needle-nose pliers to compress the locking tabs ...



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Fig. Fig. 10: ... and remove the parking brake cable from the backing plate

  1. If equipped with rear disc brakes, remove the parking brake cable from the rear disc brake adapter. Use a small prytool to compress the locking tabs on the parking brake cable retainer.
  2.  



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Fig. Fig. 11: For rear disc brakes, use a small prytool to compress the locking tabs, then remove the parking brake cable from the brake adapter

  1. Remove the parking brake cable routing bracket from the vehicle frame rail.
  2.  



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Fig. Fig. 12: Remove the routing bracket from the frame rail

  1. Remove the parking brake cable and sealing grommet from the floor pan of the vehicle.
  2.  



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Fig. Fig. 13: Disconnect the parking brake cable and sealing grommet from the floor pan

To install:
  1. Install the parking brake cable into the floor pan of the vehicle, making sure the sealing grommet is installed in the floor pan as far as possible. This will ensure a proper seal.
  2.  
  3. Install the parking brake cable into the brake support plate or rear disc brake adapter. Be sure the locking tabs on the cable retainer are expanded to ensure the cable is securely held in the support plate or adapter.
  4.  
  5. Install the parking brake routing bracket on the frame rail. Install and securely tighten the routing bracket attaching bolt.
  6.  
  7. If equipped with rear drum brakes, install the parking brake cable on the parking brake actuating lever. Then, install the actuating spring between the brake shoe assembly and the brake adjustment lever.
  8.  
  9. If equipped with rear disc brakes, install the parking brake shoe actuator lever on the parking brake cable. Then, install the parking brake shoes on the disc brake adapter.
  10.  
  11. Install the hub and bearing assembly on the spindle. Install a NEW retaining nut and tighten to 160 ft. lbs. (217 Nm).
  12.  
  13. Install the dust cap, tapping it in place with a rubber mallet. Be careful not to distort the cap when seating it.
  14.  
  15. Install the brake drum, or rotor and caliper assembly, as applicable.
  16.  
  17. Install the tire and wheel assembly, then carefully lower the vehicle.
  18.  
  19. Grab the parking brake cable-to-floor pan seal grommet with your hand, then pull it into the floor pan to be sure the seal grommet is fully seated into the floor pan.
  20.  
  21. Route the parking brake cable under the carpeting and up to the parking brake cable retaining bracket on the floor pan. Then, install the parking brake cable into the retaining bracket. Make sure the tabs on the parking brake cable retainer have expanded out to hold the cable in the bracket.
  22.  



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Fig. Fig. 14: Make sure the parking brake cable is installed properly in the retaining bracket

  1. Install the rear parking brake cables into the equalizer on the parking brake lever cable.
  2.  
  3. Reposition the rear carpeting.
  4.  
  5. Install both rear door sill plate scuff moldings by snapping then onto the rear door sills.
  6.  
  7. Install the lower rear seat cushion. Make sure the cushion is fully installed in the retainers on the floor pan of the vehicle.
  8.  
  9. Firmly grab the parking brake lever locking pin and quickly remove it from the parking brake lever mechanism. This will allow the parking brake lever mechanism to correctly adjust the parking brake cables.
  10.  
  11. Cycle the parking brake lever once to position the cables. Then return the lever to its released position. Check the rear wheels of the vehicle, they should rotate freely without dragging.
  12.  
  13. Fully apply the parking brake. Install the center console assembly, securing with the retaining screws.
  14.  

ADJUSTMENT



Vehicles with Rear Drum Brakes

Due to the auto adjust feature of the parking brake lever, no manual adjustment of the operating cables for the parking brake system is required. On vehicles with rear drum brakes, proper operation of the parking brake depends on proper adjustment of the rear drum brake shoes.

Vehicles with Rear Disc Brakes

Due to the auto adjust feature of the parking brake lever, no manual adjustment of the operating cables for the parking brake system is required. On vehicles that have rear disc brakes, proper adjustment depends on proper adjustment of the drum-in-hat parking brake shoes. Refer to that procedure, located later in this information for details.

 
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