Neon, 2000-2005

Brake Pads

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Removal & Installation



Except Srt-4
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 caliper to steering knuckle guide pin bolts.
  6.  
  7. Lift the caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then, slide the opposite end of the caliper out from under the machined end of the steering knuckle.
  8.  
  9. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose that will damage the hose.
  10.  
  11. Remove the brake pads from the caliper. Remove the outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then, slide the pad down and off the caliper. Pull the inboard brake pad away from the piston until the retaining clip is free from the cavity in the piston.
  12.  
  13. If required, the rotor can be removed by pulling it straight off the wheel mounting studs.
  14.  

To install:

  1. Clean all parts well. Inspect the caliper for piston seal leaks (brake fluid in and around the boot area and inboard lining) and for any ruptures of the piston dust boot. If the boot is damaged or fluid leak is visible, disassemble the caliper and install a new seal and boot (and piston, if scored).
  2.  
  3. Inspect the caliper pin bushings. Replace if damaged, dry or brittle.
  4.  
  5. Completely compress the piston into the caliper using a large C-clamp or other suitable tool.
  6.  
  7. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease.
  8.  
  9. Reinstall the rotor if removed.
  10.  
  11. Reinstall the brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake shoe assembly is positioned squarely against the face of the caliper piston.
    NOTE
    Be sure to remove the noise suppression gasket paper cover if the pads come so equipped.

  12.  
  13. Carefully position the caliper and brake shoe assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then, rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
  14.  
  15. Reinstall the caliper guide pin bolts and torque to 16 ft. lbs. (22 Nm).
  16.  
  17. Reinstall the wheels and torque the lug nuts to 100 ft. lbs. (135 Nm).
  18.  
  19. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  20.  
  21. Road test the vehicle for proper operation.

    Click image to see an enlarged view

    Fig. Disc brake pad identification

    Disc brake pad identification
  22.  

SRT-4
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    2 caliper to steering knuckle guide pin bolts
     
    Caliper from the steering knuckle. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose that will damage the hose.
     
    Brake shoes from the disc brake caliper adapter
     

  4.  
  5. If required, the rotor can be removed by pulling it straight off the wheel mounting studs.
  6.  

To install:

  1. Clean all parts well. Inspect the caliper for piston seal leaks (brake fluid in and around the boot area and inboard lining) and for any ruptures of the piston dust boot. If the boot is damaged or fluid leak is visible, disassemble the caliper and install a new seal and boot (and piston, if scored).
    NOTE
    The 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.

  2.  
  3. Install or connect the following:

    Brake shoes in the abutment shims clipped into the disc brake caliper adapter as shown in the accompanying figure

    Click image to see an enlarged view

    Fig. Install the brake shoes in the abutment shims clipped into the disc brake caliper adapter-SRT-4

    Install the brake shoes in the abutment shims clipped into the disc brake caliper adapter-SRT-4
     

  4.  
  5. Place the shoe with the wear indicator attached on the inboard side
  6.  
  7. Completely retract the caliper piston back into the bore of the caliper.
  8.  
  9. Install the caliper over the brake shoes on the brake caliper adapter. Make sure the springs on the shoes do not get caught in the hole formed into the center of the caliper housing.
  10.  
  11. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to 26 ft. lbs. (35 Nm)
  12.  
  13. Reinstall the wheels and torque the lug nuts to 100 ft. lbs. (135 Nm).
  14.  
  15. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  16.  
  17. Road test the vehicle for proper operation.
  18.  

 
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