Dodge Neon 2001, Service Manual

Page: 29 / 743

(7) Working from underneath the instrument
panel, disconnect the brake pedal push rod. Remove
the retaining clip from the end of the brake pedal
mounted stud, then slide the push rod straight off
the pin.
(8) If equipped, disconnect the clutch pedal push
rod. Depress the plastic retention clip on the end of
the clutch pedal mounted stud, while sliding the
push rod straight off the stud.
(9) Rotate the clutch master cylinder to line up the
square shaped retaining boss with the square shaped
opening in the brake pedal support bracket.
(10) Remove the (4) brake booster retaining nuts.
(11) Working from inside the engine compartment,
remove the (2) clutch fluid reservoir retaining bolts
from the dash panel.
(12) Remove the clutch master cylinder from the
dash panel by pulling it straight out. Position the
reservoir and line assembly out of the way.
(13) Remove the brake booster from the dash
panel by pulling it straight out, then rotate the
booster and slide it between the engine and the dash
panel towards the battery tray. Slide the booster
under the heater core coolant supply hoses and out of
the engine bay.
INSTALLATION - RIGHT HAND DRIVE
(1) Position the brake booster on the dash panel by
reversing the path taken to remove the booster. Slide
the booster under the plenum on the battery tray
side of the engine compartment. Slide the booster
between the engine and dash panel until it can be
installed on the right side of the dash panel.
(2) Reinstall the vacuum supply hose on the
booster check valve. Make sure the booster check
valve is firmly seated in the rubber grommet and did
not become dislodged during the booster installation.
(3) If equipped, install the clutch master cylinder
through the dash panel.
(4) Install the clutch fluid reservoir (Refer to 6 -
CLUTCH/MASTER CYLINDER - INSTALLATION).
Torque the retaining bolts to 7 N·m (62 in. lbs.).
(5) Working from underneath the instrument
panel, install the (4) brake booster retaining nuts.
Torque the nuts to 29 N·m (250 in. lbs.).
(6) Grease the brake pedal pin and slide the brake
booster push rod onto the pedal pin. Install the
retaining clip.
(7) If equipped, lock the clutch master cylinder in
position. Rotate the clutch master cylinder to line up
the square shaped retaining boss with the square
shaped opening in the brake pedal support bracket.
Once the cylinder is inserted through the brake pedal
support bracket rotate 90° to lock it in position.
(8) Connect the clutch pedal push rod. Slide the
push rod on the clutch pedal mounted stud until the
plastic retention clip locks it in place.
(9) Install the coolant reservoir (Refer to 7 -
COOLING/ENGINE/COOLANT RECOVERY CON-
TAINER - INSTALLATION). Torque the retaining
bolts to 7 N·m (62 in. lbs.). Connect the coolant over-
flow hose on the thermostat housing.
(10) Install the heater core coolant supply tube
support bracket bolts (Fig. 15). Torque the bolts to 36
N·m (27 ft. lbs.).
(11) Install the battery and battery tray in the
vehicle (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/TRAY - INSTALLATION) (Refer to 8 - ELEC-
TRICAL/BATTERY
SYSTEM/BATTERY -
INSTALLATION).
(12) Install the air cleaner assembly (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
(13) Install the master cylinder on the vehicle.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
MASTER CYLINDER - INSTALLATION) (Refer to 5
-
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION).
(14) Fill the brake fluid reservoir to specification
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID - STANDARD PROCEDURE).
(15) Bleed the air from the hydraulic brake system
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
WARNING: Be certain a firm brake pedal is
achieved before attempting to move the vehicle.
PROPORTIONING VALVE
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE
If premature rear wheel skid occurs on a hard
brake application, it could be an indication that a
malfunction has occurred with one of the proportion-
ing valves.
One proportioning valve controls the right rear
brake, and the other proportioning valve controls the
left rear brake (Fig. 16). Therefore, a road test to
determine which rear brake skids first is essential.
Before testing the proportioning valve in question,
inspect the rear brake linings for contamination or
for replacement shoes not meeting the OEM brake
lining material specifications.
The proportioning valve should always be tested
prior to being replaced.
5s - 16 BRAKES-BASE
PL
POWER BRAKE BOOSTER-RHD (Continued)
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2001 NEON