Dodge Ram Truck 1500-2500-3500. Manual — part 201

REAR

CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to
hang the caliper securely.

1. Raise and support vehicle.

2. Remove the wheel and tire assembly.

3. Drain small amount of fluid from master cylinder

brake reservoir with suction gun.

4. Remove the brake hose banjo bolt and discard the

copper washers if replacing caliper.

5. Remove the caliper slide bolts (3).

6. Remove the caliper (6) from vehicle.

REAR - SRT-10

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3. Compress

the

disc

brake

caliper

using

tool

#C4212F.

4. Remove the caliper pin bolts (3).

5. Remove the banjo bolt (6) and discard the copper

washer.

CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose with result. Provide a suitable support to
hang the caliper securely.

6. Remove the rear disc brake caliper.

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BRAKES - BASE - SERVICE INFORMATION

DR/DH

DISASSEMBLY

DISC BRAKE CALIPER

1. Drain the brake fluid from caliper.

2. C-clamp (2) a block of wood (1) over one piston.

3. Take another piece of wood and pad it with one-

inch thickness of shop towels (2). Place this piece
in the outboard shoe side of the caliper in front of
the other piston. This will cushion and protect cali-
per piston during removal.

4. To remove the caliper piston direct short bursts of

low pressure air with a blow gun through the cal-
iper brake hose port. Use only enough air pressure
to ease the piston out.

CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.

5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston

removed. This will seal the empty piston bore.

6. Move the padded piece of wood in front of the other piston.

7. Remove the second piston using the same procedure with short bursts of low pressure air.

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BRAKES - BASE - SERVICE INFORMATION

5 - 233

8. Remove piston dust boots (2) with a suitable pry

tool.

CAUTION:

Do

not

scratch

piston

bore

while

removing the seals.

9. Remove piston seals (3) from caliper (1).

10. Push caliper mounting bolt bushings (3) out of the

boot seals (2) and remove the boot seals from the
caliper (1).

11. Remove caliper bleed screw.

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BRAKES - BASE - SERVICE INFORMATION

DR/DH

DISC BRAKE CALIPER - FRONT - SRT-10

NOTE: Before disassembling caliper, clean and
inspect it. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPER - CLEANING)
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPER - INSPECTION)

1. Remove front disc brake caliper (1) from vehicle.

(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPER - REMOVAL).

2. If brake pads were not removed from caliper prior

to removing caliper from vehicle, remove brake
pads (6). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/pads - REMOVAL)

3. Remove transfer brake tube (5) between inboard

and outboard caliper halves.

4. Install M10 X 1.0 threaded plug(2) in flex hose

banjo bolt hole (1). This hole needs to be plugged
to remove caliper inboard pistons using com-
pressed air.

5. Install C-clamp (2) over inboard caliper piston near-

est to bleeder screw as follows:

a. Lay shop towel (3) over outside of inboard cal-

iper half to protect finish.

b. Place Installer, Special Tool 6454 (5), 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 towel as

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

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BRAKES - BASE - SERVICE INFORMATION

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