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Change front disc brakes - 2000 Dodge Neon

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  • Dodge Master
  • 2,984 Answers

Except Srt-4

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove the front wheels.
  3. Remove the 2 caliper to steering knuckle guide pin bolts.
  4. 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.
  5. 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.
  6. 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.
  7. If required, the rotor can be removed by pulling it straight off the wheel mounting studs.
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. Inspect the caliper pin bushings. Replace if damaged, dry or brittle.
  3. Completely compress the piston into the caliper using a large C-clamp or other suitable tool.
  4. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease.
  5. Reinstall the rotor if removed.
  6. 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.

  7. 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.
  8. Reinstall the caliper guide pin bolts and torque to 16 ft. lbs. (22 Nm).
  9. Reinstall the wheels and torque the lug nuts to 100 ft. lbs. (135 Nm).
  10. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  11. Road test the vehicle for proper operation.

change front disc brakes - 83b8db3.gif

Posted on Apr 23, 2010

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SECTION 206-03: Front Disc Brake 1999 Escort/Tracer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 06/06/1998 Front Disc Brake Front Disc Brake System Components
Item Part Number Description 1 1125 Front Disc Brake Rotor 2 2B296 Disc Brake Caliper Locating Pin 3 2B120 Disc Brake Caliper 4 2001 Brake Pads 5 - Copper Washers (2 Req'd) 6 - Banjo Bolt 7 2078 Front Brake Hose 8 2W303 Brake Caliper Bolt- (2 Req'd) 9 2814 Brake Hose Clip The front disc brake system consists of a single-piston front disc brake caliper (2B120) and a ventilated front disc brake rotor (1125). The brake shoes and linings (2001) are held in the front disc brake caliper by two front disc brake caliper locating pins (2B296) and two springs. The inboard brake shoe and lining is equipped with a wear indicator that makes a squealing noise when the brake shoes and linings are worn beyond recommended use.

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Section 06-03: Brakes, Front Disc 1999 Taurus, Sable Workshop Manual REMOVAL AND INSTALLATION Brake Shoe and Lining Removal
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  1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120) , front disc brake rotor shield (2K004) or front wheel knuckle (3K185) .
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-----------------------------------------------------------------
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1999 Taurus/Sable Section 06-03: Brakes, Front Disc 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Disc Removal
  1. Raise vehicle on hoist.
  1. Remove wheel and tire assembly. Be careful to avoid damage or interference with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
  1. ani_caut.gif CAUTION: Handle front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a way as to prevent deformation of front disc brake rotor , and nicking, scratching or contamination of brake linings/rotor surfaces.
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Installation
  1. If original front disc brake rotor is being installed, make sure rotor braking and mounting surfaces are clean.
  1. ani_caut.gif CAUTION: Failure to clean rust and foreign material from rotor and hub mounting faces when installing new or old front disc brake rotors will result in high rotor runout, which will speed up the development of brake roughness shudder vibration.
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  1. Install front disc brake rotor on wheel hub assembly.
  1. Install disc brake caliper and new caliper anchor bracket bolts on front disc brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
  1. ani_caut.gif CAUTION: Failure to tighten lug nuts (1012) in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
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The hard part is pressing the caliper piston abck into the caliper so you can get the new, thicker pads over the rotor. A large C Clamp works best.

SECTION 206-03: Front Disc Brake 2001 Villager Workshop Manual
REMOVAL AND INSTALLATION Pads —Front Disc Brake Removal
  1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
  1. Remove the front disc brake caliper bolts. torx bit. T20?
  1. Support the front disc brake caliper from the front strut and spring assembly using mechanics wire.
  1. Remove the front disc brake pads.
    1. Remove the outboard front disc brake pad.
    1. Remove the inboard front disc brake pad.
Installation
  1. s1v~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Make sure the master cylinder reservoir does not overfill and spill brake fluid while retracting the front disc brake caliper piston.
    NOTE: It is necessary to fully retract the front disc brake caliper piston in the bore before installing the front disc brake pads.
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    1. Install the inboard front disc brake pad.
    1. Install the outboard front disc brake pad.
Caution. The outer pads are left and right. put left on driver side.
  1. Position the front disc brake caliper on the front-wheel knuckle and install the brake caliper pin bolts.
  1. s1v~us~en~file=ani_caut.gif~gen~ref.gif WARNING: It is necessary to depress the brake pedal several times to position the front disc brake caliper piston before driving the vehicle.

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