Dodge Ram Truck 1500-2500-3500. Manual — part 203

ASSEMBLY

DISC BRAKE CALIPER

CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.

1. Lubricate caliper pistons, piston seals and piston

bores with clean, fresh brake fluid.

NOTE: Verify seal is fully seated and not twisted.

2. Install new piston seals (3) into caliper bores (2).

3. Lightly lubricate lip of new boot with silicone

grease. Install boot on piston and work boot lip into
the groove at the top of piston (3).

4. Stretch boot (2) rearward to straighten boot folds,

then move boot forward until folds snap into place.

5. Install piston (3) into caliper bore and press piston

down to the bottom of the caliper bore by hand or
with hammer handle.

6. Seat dust boot in caliper (2) with Handle C-4171

(1) and Installer (3):

•

54 mm caliper: Installer C-3716-A

7. Install the second piston and dust boot.

8. Lubricate caliper mounting bolt bushings, boot

seals and bores with Mopar brake grease or Dow
Corning

T

807 grease only.

CAUTION: Use of alternative grease may cause
damage to the boots seals.

9. Install the boot seals into the caliper seal bores

and center the seals in the bores.

10. Install mounting bolt bushings into the boot seals

and insure seal lip is engaged into the bushing
grooves at either end of the bushing.

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BRAKES - BASE - SERVICE INFORMATION

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11. Install caliper bleed screw.

DISC BRAKE CALIPER - FRONT - SRT-10

NOTE: Perform Step 1 through Step 4 for each piston and bore of caliper. Keep in mind there are two dif-
ferent size pistons, bores, seals and boots used on each caliper.

1. Dip NEW piston seal in fresh clean Mopar

T

brake fluid conforming to DOT 4 specifications. By hand, gently work

seal into seal groove in caliper piston bore until the seal is properly seated.

2. Lightly coat inside of NEW dust boot (1) with fresh

clean Mopar

T

brake fluid conforming to DOT 4

specifications. Install dust boot on caliper piston
(3). Be sure dust boot is completely seated in
retaining groove (2) of caliper piston.

CAUTION: When installing piston (3), force must
be applied to the piston uniformly to avoid cock-
ing and binding the piston in the bore.

3. Squarely position piston (3) into top portion of pis-

ton bore. Using finger pressure, evenly apply pres-
sure to top of piston, pressing it into bore until it is
past piston seal, bottomed in bore.

4. Using finger pressure, press outer ring of dust boot

into retaining groove surrounding caliper bore until
flush with caliper machined surface.

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BRAKES - BASE - SERVICE INFORMATION

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5. Repeat above procedure for remaining pistons and

bores.

6. Install bleeder screws in top of caliper.

7. Install transfer brake fluid tube (5) between inboard

and outboard caliper halves. Tighten tube nuts to
17 N·m (145 in. lbs.) torque.

8. Install brake pads (6) in caliper (1). (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - INSTALLATION)

9. Install caliper (1) on vehicle. (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/DISC

BRAKE

CALI-

PER - INSTALLATION)

INSTALLATION

FRONT

NOTE: Install a new copper washers on the banjo
bolt when installing

1. Install the disc brake caliper (2).

CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.

2. Install the banjo bolt with new copper washers to

the caliper. Tighten to 27 N·m (20 ft. lbs.)

3. Install the caliper slide pin bolts. tighten to 32 N·m

(24 ft. lbs.)

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

BRAKES/HYDRAULIC/MECHANICAL

-

STAN-

DARD PROCEDURE).

5. Install the tire and wheel assembly, (Refer to 22 -

TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).

6. Lower the vehicle.

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BRAKES - BASE - SERVICE INFORMATION

DR/DH

FRONT - SRT-10

NOTE: Install a new copper washers on the banjo
bolt when installing

1. Install the disc brake pads, anti-rattle springs (2)

and pad retaining pin (3).

2. Install the disc brake caliper (1).

CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.

3. Install the brake hose (2) banjo bolt (1) with new

copper washers to the caliper. Tighten to 27 N·m
(20 ft. lbs.)

4. Install the caliper mounting bolts (3). tighten to 32

N·m (24 ft. lbs.).

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

BRAKES/HYDRAULIC/MECHANICAL

-

STAN-

DARD PROCEDURE).

6. Install the tire and wheel assembly, (Refer to 22 -

TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).

7. Lower the vehicle.

DR/DH

BRAKES - BASE - SERVICE INFORMATION

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