Dodge Ram Truck 1500-2500-3500. Manual — part 205

INSTALLATION

1. Install the caliper adapter mount (1) on the axle

housing (2).

2. Install support plate on axle flange. Tighten attach-

ing bolts (3) to 68 N·m (50 ft. lbs.) LD or tighten to
203 N·m (150 ft.lbs.) HD.

3. Install parking brake cable in the brake lever.

4. Install the park brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLATION)..

5. Install axle shaft, (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE SHAFTS - INSTALLA-

TION).

6. Adjust brake shoes to drum with brake gauge (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - ADJUST-

MENTS).

7. Install the rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION).

8. Install the caliper adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER

- INSTALLATION).

9. Install the caliper (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLA-

TION).

10. Install wheel and tire assembly.

FLUID

DIAGNOSIS AND TESTING

BRAKE FLUID CONTAMINATION

Indications of fluid contamination are swollen or deteriorated rubber parts.

Swollen rubber parts indicate the presence of petroleum in the brake fluid.

To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers,
there is mineral oil or other fluid contamination of the brake fluid.

If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, cal-
iper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses.

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BRAKES - BASE - SERVICE INFORMATION

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STANDARD PROCEDURE

BRAKE FLUID LEVEL

Always clean the master cylinder reservoir (1) and cap
(2) before checking fluid level. If not cleaned, dirt
could enter the fluid.

The fluid fill level is indicated on the side of the master
cylinder reservoir (1).

The correct fluid level is to the MAX indicator on the
side of the reservoir. If necessary, add fluid to the
proper level.

SPECIFICATIONS

BRAKE FLUID

The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an
equivalent from a tightly sealed container.

CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open
container of brake fluid will absorb moisture from the air and contaminate the fluid.

CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type
fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake
system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid,
etc.

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BRAKES - BASE - SERVICE INFORMATION

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RESERVOIR-FLUID

REMOVAL

1. Install the prop rod on the brake pedal to keep

pressure on the brake system.

2. Remove the reservoir cap (1) and siphon fluid into

a drain container.

3. Remove the electrical connector from the fluid level

switch (3) in the reservoir (2).

4. Remove the reservoir mounting bolt (5).

5. Remove the reservoir (2) from the master cylinder

(4) by pulling upwards.

6. Remove old grommets from cylinder body.

INSTALLATION

CAUTION: Do not use any type of tool to install
the grommets. Tools may cut, or tear the grom-
mets creating a leak problem after installation.
Install the grommets using finger pressure only.

1. Lubricate the new grommets (6) with clean brake

fluid and Install new grommets in cylinder body.
Use finger pressure to install and seat grommets
(6).

2. Start the reservoir (2) in grommets (6). Then rock

the reservoir back and forth while pressing down-
ward to seat it into the grommets.

3. Install the mounting bolt (5) for the reservoir (2) to

the master cylinder (4).

4. Reconnect the electrical connector to the fluid res-

ervoir level switch (3).

5. Remove the prop rod from the vehicle.

6. Fill and bleed base brake system, (Refer to 5 - BRAKES - STANDARD PROCEDURE).

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BRAKES - BASE - SERVICE INFORMATION

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BRAKE JUNCTION BLOCK

REMOVAL

1. Remove the brake lines (1) from the junction block

(2).

2. Remove the junction block (2) mounting bolt and

remove the junction block from the bracket.

INSTALLATION

1. Position the junction block (2) on the bracket and

install the mounting bolt. Tighten the mounting bolt
to 23 N·m (210 in. lbs.).

2. Install the brake lines (1) into the junction block (2)

and tighten to 19-23 N·m (170-200 in. lbs.).

3. Bleed the base brake system, (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL

-

STAN-

DARD PROCEDURE).

MASTER CYLINDER

DESCRIPTION

A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons
is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores
reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. The reservoir is
the only serviceable component.

The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the
equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir
compartments will retain enough fluid to operate the functioning hydraulic circuit.

Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder
fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading.

The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder
is not a repairable component.

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