Dodge Ram Truck 1500-2500-3500. Manual — part 202

6. Place an appropriate size block (1) of wood inside

center area of caliper, in front of first piston to be
removed. Block of wood should be large enough to
allow piston to exit piston bore just far enough for
piston to be pulled out remaining distance by hand,
but not exit the bore completely.

WARNING: DO NOT PLACE FACE OR HANDS
NEAR PISTONS OR INTO CENTER AREA OF CAL-
IPER

WHEN

USING

COMPRESSED

AIR

TO

REMOVE PISTONS FROM BORE OF CALIPER.
PERSONAL INJURY CAN RESULT FROM SUCH
ACTION.

WARNING:

UNDER

NO

CONDITIONS

SHOULD

HIGH PRESSURE AIR BE USED TO REMOVE PIS-
TON FROM CALIPER BORE. PERSONAL INJURY CAN RESULT FROM SUCH ACTION.

7. Using a rubber tipped air nozzle (4), apply short bursts of low pressure compressed air to caliper transfer port to

force piston from bore.

8. Remove block of wood (1) from center area of caliper.

9. Remove piston from caliper bore, but leave piston dust boot in place.

10. Transfer C-clamp (3) and Installer to cover piston boot and bore where piston was just removed. It may be

necessary to place a small piece of rubber over hole in center of Installer to seal off installer.

11. Place block of wood (1) inside center area of caliper, in front of second piston to be removed.

12. Using a rubber tipped air nozzle (4), apply short bursts of low pressure compressed air to caliper transfer port

to force piston from bore.

13. Remove block of wood (1) from center area of caliper.

14. Remove piston from caliper bore.

15. Remove C-clamp (3) and Installer.

16. Remove piston dust boots (1) from empty piston

bores of caliper. To do so, carefully pry each boot
from its retaining groove using a small screw-
driver. The screwdriver must be inserted between
outer edge of dust boot and caliper. Do not insert
screwdriver into bore of caliper to remove
boot; scoring of bore may occur.

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BRAKES - BASE - SERVICE INFORMATION

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17. Remove piston seal (1) from each empty piston

bores using a trim stick (2) or other suitable tool.
Do not use a screwdriver or other metal tool;
scoring of bore or burring of seal groove may
occur.

18. Remove bleeder screw from inboard half of cali-

per.

19. Remove threaded plug (2) from banjo bolt hole (1)

in inboard half of caliper.

20. Install C-clamp (2) over outboard caliper piston

nearest to bleeder screw as follows:

a. Lay shop towel (3) over outside of outboard

caliper half to protect finish.

b. Place Installer, Special Tool 6454 (4) , over pis-

ton and boot nearest to bleeder screw and
hold in place. Either side of Installer will work.

c. Place C-clamp (2) over tool and cloth as

shown and tighten C-clamp. DO NOT USE
EXCESSIVE FORCE; excessive force could
damage caliper or piston.

21. Place an appropriate size block of wood (1) inside

center area of caliper, in front of piston nearest
transfer tube port. Block of wood should be large
enough to allow piston to exit piston bore just far
enough for piston to be pulled out remaining distance by hand, but not exit the bore completely.

DR/DH

BRAKES - BASE - SERVICE INFORMATION

5 - 237

WARNING: DO NOT PLACE FACE OR HANDS
NEAR PISTONS OR INTO CENTER AREA OF CAL-
IPER

WHEN

USING

COMPRESSED

AIR

TO

REMOVE PISTONS FROM BORE OF CALIPER.
PERSONAL INJURY CAN RESULT FROM SUCH
ACTION.

WARNING:

UNDER

NO

CONDITIONS

SHOULD

HIGH PRESSURE AIR BE USED TO REMOVE PIS-
TON FROM CALIPER BORE. PERSONAL INJURY
CAN RESULT FROM SUCH ACTION.

22. Using a rubber tipped air nozzle, apply short

bursts of low pressure compressed air to caliper
transfer port to force piston from bore.

23. Remove block of wood (1) from center area of

caliper.

24. Remove piston from caliper bore, but leave piston dust boot in place.

25. Transfer C-clamp (2) and Installer to cover piston boot and bore where piston was just removed. It may be

necessary to place a small piece of rubber over hole in center of Installer to seal off installer.

26. Place the piece of wood (1) inside center area of caliper, in front of piston to be removed.

27. Using a rubber tipped air nozzle, apply short bursts of low pressure compressed air to caliper transfer port to

force piston from bore.

28. Remove piece of wood from center area of caliper.

29. Remove piston from caliper bore.

30. Remove C-clamp and Installer.

31. Remove piston dust boots (1) from empty piston

bores of outboard half of caliper. To do so, care-
fully pry each boot from its retaining groove (2)
using a small screwdriver. The screwdriver must
be inserted between outer edge of dust boot and
caliper. Do not insert screwdriver into bore of
caliper to remove boot; scoring of bore may
occur.

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BRAKES - BASE - SERVICE INFORMATION

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32. Remove piston seal (1) from each empty piston

bore of outboard half of caliper using a trim stick
(2) or other suitable tool. Do not use a screw-
driver or other metal tool; scoring of bore or
burring of seal groove may occur.

33. Remove bleeder screw on outboard half of

caliper.

34. Thoroughly clean each of the four pistons using Mopar

T

Non-Clorinated Brake Parts Cleaner, alcohol or other

suitable solvent and wipe dry using a lint free towel. Inspect all surfaces of each piston for any signs of cor-
rosion or scoring. If any corrosion on piston cannot be removed using these products, or if piston is scored,
replace piston. Do not sand piston to remove corrosion or scoring.

CAUTION: Do not attempt to hone piston bores of this caliper. If bores cannot be cleaned using appropriate
solvents, caliper must be replaced.

35. Clean piston bores of caliper using Mopar

T

Non-Clorinated Brake Parts Cleaner, alcohol or another suitable

solvent saturated into a lint free towel. Once thoroughly cleaned, wipe each bore dry using a clean lint free
towel. Inspect all surfaces inside caliper bores for any signs of corrosion or scoring. If any corrosion inside
piston bores cannot be removed using these products, or if any bore is scored, the caliper assembly must be
replaced.

36. Using compressed air, blow out piston bores of caliper to remove any particles that may be left from cleaning

procedure and to ensure bore is dry.

37. Proceed to Assembly to assemble caliper. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE

CALIPER - ASSEMBLY)

INSPECTION

The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.

The piston must be replaced if cracked or scored. Do
not attempt to restore a scored piston surface by
sanding or polishing.

CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.

The bore can be lightly polished with a brake hone
(3) to remove very minor surface imperfections. The
caliper should be replaced if the bore is severely cor-
roded, rusted, scored, or if polishing would increase
bore diameter more than 0.025 mm (0.001 inch).

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