Neon, 2000-2005

Brake Caliper

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Isolate the master cylinder as follows:
    1. Use a brake pedal holding tool and depress the brake pedal past its first one inch of travel and hold it in this position. (This will keep brake fluid from draining from the master cylinder).
    2.  

  4.  
  5. Remove or disconnect the following:

    Rear wheels
     
    Banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers.
     
    2 caliper guide pin bolts
     
    Caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor, and then lifting the caliper assembly off the machined abutment on the adapter

    Click image to see an enlarged view

    Fig. View of the brake pedal holding tool-all models

    View of the brake pedal holding tool-all models

    Click image to see an enlarged view

    Fig. Exploded view of the rear brake caliper mounting

    Exploded view of the rear brake caliper mounting
     

  6.  

To install:


NOTE
When installing new brake components, be sure to use correct parts. Parts designed for the BR3 Performance Brake System must not be mixed with other brake systems.

  1. If new pad were installed, completely retract the caliper piston back into piston bore of the caliper.
  2.  
  3. Lubricate both adapter caliper slide abutments with a liberal amount of Mopar® Multipurpose Lubricant, or an equivalent.
    WARNING
    Be careful when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter.

  4.  
  5. Starting with the lower end, carefully lower the caliper and brake shoes over the brake rotor and catch the caliper-s bottom edge behind the caliper slide abutment. Rotate the top of the caliper into mounting position on the adapter.
    WARNING
    Be very careful not to cross thread the caliper guide pin bolts when you are installing them!

  6.  
  7. Install or connect the following:

    Caliper guide pin bolts, then carefully torque them to 16 ft. lbs. (22 Nm)
     
    Banjo bolt connecting the brake hose to the brake caliper. Install new washers, one on each side of the hose fitting as the banjo bolt is guided through the fitting. Torque the banjo bolt to 18 ft. lbs. (24 Nm).
     
    Tire and wheel. Torque the lug nuts to 100 ft. lbs. (135 Nm).
     

  8.  
  9. Remove the brake pedal holding tool.
  10.  
  11. Properly bleed the brake system.
  12.  
  13. Reinstall the front wheels and lower the vehicle.
  14.  
  15. Pump the brake pedal to seat the front brake pads before moving the vehicle.
  16.  
  17. Road test the vehicle and check for proper operation.
  18.  

 
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