DODGE RAM 1500 1998 2.G Workshop Manual

(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 8).
(8) Remove the hose.
REMOVAL - REAR TUBE / HOSE ASSEMBLY
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line located at the axle.
(4) Remove the mounting bolt for the brake hose
at the axle (Fig. 9).
(5) Remove the banjo bolt at the caliper (Fig. 9).
(6) Remove the hose.
REMOVAL - FRONT HOSE
(1) Install a prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove the tire and wheel assembly.
(4) Remove the brake hose from the brake line
located at the frame (Fig. 10).
(5) Remove the brake hose banjo bolt at the caliper
(Fig. 10).
(6) Remove the mounting bolt securing the brake
hose to the frame and remove the wheel speed sensor
wire from the brake hose (Fig. 10).
(7) Remove the hose.
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 8).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 8).
(4) Install the vent tube (Fig. 8).
(5) Install the brake hose clip at the top of the
hose located at the frame (Fig. 7).
(6) Install the brake line to the hose at the frame
(Fig. 7).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
Fig. 8 REAR HOSE
1 - BRAKE HOSE
2 - VENT HOSE
3 - BRAKE LINES
Fig. 9 BRAKE LINE WITH RUBBER HOSE
1 - BANJO BOLT
2 - MOUNTING BOLT
3 - REAR TUBE / HOSE ASSEMBLY
Fig. 10 BRAKE HOSE MOUNTED PASSENGER SIDE
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BANJO BOLT
4 - WHEEL SPEED SENSOR WIRE
5 - 12 BRAKES - BASEDR
BRAKE LINES (Continued)

INSTALLATION - REAR TUBE / HOSE
ASSEMBLY
(1) Install the hose.
(2) Install the banjo bolt at the caliper (Fig. 9) and
tighten fitting bolt to 27 N´m (245 in. lbs.).
(3) Install the mounting bolt for the brake hose at
the axle (Fig. 9).
(4) Install the brake line located at the axle.
(5) Lower the vehicle and remove the support.
(6) Remove the prop rod.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the frame (Fig. 11).
(3) Install the brake hose banjo bolt at the caliper
(Fig. 10).
(4) Reinstall the wheel speed sensor wire to the
brake hose (Fig. 10).
(5) Remove the support and lower the vehicle.
(6) Remove the prop rod from the brake pedal.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT
(1) Raise and support vehicle.
(2) Remove the wheel and tire assemblies.(3) Compress the caliper.
(4) Remove the caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL).
(5) Remove the caliper by tilting the top up and off
the caliper adapter (Fig. 12).
NOTE: Do not allow brake hose to support caliper
assembly.
(6) Support and hang the caliper. (Fig. 13)
(7) Remove the inboard brake shoe from the cali-
per adapter (Fig. 14).
Fig. 11 BRAKE HOSE MOUNT DRIVERS SIDE
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR WIRE
3 - BRAKE HOSE
Fig. 12 Caliper
1 - CALIPER
2 - CALIPER ADAPTER
Fig. 13 DISC BRAKE CALIPER - FRONT
1 - STEERING KNUCKLE
2 - DISC BRAKE CALIPER
3 - CALIPER MOUNTING ADAPTER
4 - DISC BRAKE ROTOR
DRBRAKES - BASE 5 - 13
BRAKE LINES (Continued)

(8) Remove the outboard brake shoe from the cali-
per adapter (Fig. 15).
(9) Remove the anti-rattle springs from the caliper
adapter (Fig. 16) and (Fig. 17).NOTE: Anti-rattle springs are not interchangeable.
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the rear wheel and tire assemblies.
(3) Compress the caliper.
(4) Remove caliper slide bolts
NOTE: Do not allow brake hose to support caliper
assembly.
(5) Remove the caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) and then tilt the top up and off the cal-
iper adapter (Fig. 18) or (Fig. 19).
(6) Remove inboard brake shoe from the caliper
adapter (Fig. 20).
Fig. 14 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 15 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
Fig. 16 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 17 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
5 - 14 BRAKES - BASEDR
BRAKE PADS/SHOES (Continued)

(7) Remove outboard brake shoe from caliper
adapter (Fig. 21).
(8) Remove the anti-rattle springs from the caliper
adapter (Fig. 22) and (Fig. 23).
NOTE: Anti-rattle springs are not interchangeable.
Fig. 18 DISC BRAKE CALIPER - REAR
1 - CALIPER ADAPTER
2 - CALIPER ADAPTER MOUNTING BOLTS
3 - CALIPER SLIDE BOLTS
4 - BRAKE HOSE
5 - CABLE
6 - CALIPER
7 - ROTOR
8 - ANTI-RATTLE CLIPS
Fig. 19 ROTOR / PADS/ CALIPER DUAL REAR
WHEELS
1 - Rotor
2 - Brake Shoes
3 - Disc Brake Caliper
Fig. 20 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 21 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
DRBRAKES - BASE 5 - 15
BRAKE PADS/SHOES (Continued)

INSTALLATION
INSTALLATION - FRONT
(1) Bottom pistons in caliper bore with C-clamp.
Place an old brake shoe between a C-clamp and cal-
iper piston.
(2) Clean caliper mounting adapter and anti-rattle
springs.
(3) Lubricate anti-rattle springs with Mopar brake
grease.
(4) Installnewanti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
(5) Install inboard brake shoe in adapter.
(6) Install outboard brake shoe in adapter.(7) Tilt the top of the caliper over rotor and under
adapter. Then push the bottom of the caliper down
onto the adapter.
(8) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(9) Install wheel and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(10) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(11) Top off master cylinder fluid level.
INSTALLATION - REAR
(1) Clean caliper mounting adapter and anti-rattle
springs.
(2) Lubricate anti-rattle springs with Mopar brake
grease.
(3) Installnewanti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
(4) Install inboard brake shoe in adapter.
(5) Install outboard brake shoe in adapter.
(6) Tilt the bottom of the caliper over rotor and
under adapter. Then push the top of the caliper down
onto the adapter.
(7) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION) (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/DISC BRAKE CALIPERS -
INSTALLATION).
(8) Install wheel and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(9) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(10) Top off master cylinder fluid level.
DISC BRAKE CALIPERS
DESCRIPTION
The calipers are a single piston type in the rear
and dual piston type in the front. The calipers are
free to slide laterally, this allows continuous compen-
sation for lining wear.
OPERATION
When the brakes are applied fluid pressure is
exerted against the caliper piston. The fluid pressure
is exerted equally and in all directions. This means
pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 24).
Fluid pressure applied to the piston is transmitted
directly to the inboard brake pad. This forces the pad
lining against the inner surface of the disc brake
Fig. 22 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 23 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
5 - 16 BRAKES - BASEDR
BRAKE PADS/SHOES (Continued)

rotor. At the same time, fluid pressure within the pis-
ton bore forces the caliper to slide inward on the
mounting bolts. This action brings the outboard
brake pad lining into contact with the outer surface
of the disc brake rotor.
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will attempt to stop the rotors from turning and
bring the vehicle to a stop.
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake pads do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seal controls the amount of pis-
ton extension needed to compensate for normal lining
wear.
During brake application, the seal is deflected out-
ward by fluid pressure and piston movement (Fig.
25). When the brakes (and fluid pressure) are
released, the seal relaxes and retracts the piston.
The amount of piston retraction is determined by
the amount of seal deflection. Generally the amountis just enough to maintain contact between the pis-
ton and inboard brake pad.
REMOVAL
REMOVAL - FRONT
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) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the tire and wheel assembly.
(4) Compress the disc brake caliper.
(5) Remove the banjo bolt and discard the copper
washer.
(6) Remove the caliper slide bolts.
(7) Remove the disc brake caliper (Fig. 26) or (Fig.
27).
REMOVAL - 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) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove the wheel and tire assembly.
(4) Drain small amount of fluid from master cylin-
der brake reservoir with suction gun.
(5) Remove the brake hose banjo bolt and discard
the copper washers if replacing caliper (Fig. 28).
Fig. 24 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
Fig. 25 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
DRBRAKES - BASE 5 - 17
DISC BRAKE CALIPERS (Continued)

(6) Remove the caliper slide bolts (Fig. 28).
(7) Remove the caliper from vehicle.
DISASSEMBLY
(1) Drain the brake fluid from caliper.
(2) C-clamp a block of wood over one piston (Fig.
29).
(3) Take another piece of wood and pad it with
one-inch thickness of shop towels. Place this piece in
the outboard shoe side of the caliper in front of the
other piston. This will cushion and protect caliper
piston during removal (Fig. 30).(4) To remove the caliper piston directshort
bursts of low pressure airwith a blow gun
through the caliper 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.
Fig. 26 DISC BRAKE CALIPER - FRONT
1 - STEERING KNUCKLE
2 - DISC BRAKE CALIPER
3 - CALIPER MOUNTING ADAPTER
4 - DISC BRAKE ROTOR
Fig. 27 8 LUG ROTOR & CALIPER ASSEMBLY
1 - ROTOR
2 - CALIPER ADAPTER
3 - ANTI-RATTLE CLIPS
4 - BRAKE HOSE WITH BANJO BOLT
5 - DISC BRAKE CALIPER
6 - OUTBOARD BRAKE PAD
Fig. 28 DISC BRAKE CALIPER - REAR
1 - CALIPER ADAPTER
2 - CALIPER ADAPTER MOUNTING BOLTS
3 - CALIPER SLIDE BOLTS
4 - BRAKE HOSE
5 - CABLE
6 - CALIPER
7 - ROTOR
8 - ANTI-RATTLE CLIPS
Fig. 29 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
5 - 18 BRAKES - BASEDR
DISC BRAKE CALIPERS (Continued)

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 pro-
cedure withshort bursts of low pressure air.
(8) Remove piston dust boots with a suitable pry
tool (Fig. 31).
(9) Remove piston seals from caliper (Fig. 32).CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Push caliper mounting bolt bushings out of
the boot seals and remove the boot seals from the
caliper (Fig. 33).
(11) Remove caliper bleed screw.
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.
Fig. 30 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 31 Piston Dust Boot Removal
1 - CALIPER
2 - DUST BOOT
Fig. 32 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 33 Bushings And Boot Seals
1 - CALIPER
2 - BUSHING
3 - BOOT SEAL
DRBRAKES - BASE 5 - 19
DISC BRAKE CALIPERS (Continued)

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 belightlypolished with a brake
hone to remove very minor surface imperfections
(Fig. 34). The caliper should be replaced if the bore is
severely corroded, rusted, scored, or if polishing
would increase bore diameter more than 0.025 mm
(0.001 inch).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubricate caliper pistons, piston seals and pis-
ton bores with clean, fresh brake fluid.
(2) Install new piston seals into caliper bores (Fig.
35).
NOTE: Verify seal is fully seated and not twisted.
(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.
(4) Stretch boot rearward to straighten boot folds,
then move boot forward until folds snap into place.
(5) Install piston into caliper bore and press piston
down to the bottom of the caliper bore by hand or
with hammer handle (Fig. 36).
(6) Seat dust boot in caliper (Fig. 37) with Handle
C-4171 and Installer:
²HD 56 mm caliper: Installer C-4340
²LD 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
Corningt807 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.
(11) Install caliper bleed screw.
Fig. 34 Polishing Piston Bore
1 - HONE
2 - CALIPER
3 - PISTON BORE
Fig. 35 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 36 Caliper Piston Installation
1 - CALIPER
2 - DUST BOOT
3 - PISTON
5 - 20 BRAKES - BASEDR
DISC BRAKE CALIPERS (Continued)

INSTALLATION
INSTALLATION - FRONT
NOTE: Install a new copper washers on the banjo
bolt when installing
(1) Install the disc brake caliper (Fig. 26) or (Fig.
27).
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) Remove the prop rod.
(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 PRO-
CEDURE).
(7) Lower the vehicle.
INSTALLATION - REAR
(1) Install caliper to the caliper adapter.
(2) Coat the caliper mounting slide pin bolts with
silicone grease. Then install and tighten the bolts to
15 N´m (11 ft. lbs.).
(3) Install the brake hose banjo bolt if removed.
(4) Install the brake hose to the caliper withnew
seal washersand tighten fitting bolt to 27 N´m (245
in. lbs.).CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Remove the prop rod from the vehicle.
(6) Bleed the base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(7) Install the wheel and tire assemblies (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
DISC BRAKE CALIPER
ADAPTER
REMOVAL
REMOVAL - FRONT
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the bolts securing the caliper adapter
to the steering knuckle (Fig. 38)
(5) Remove the caliper adapter.
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Drain a small amount of fluid from master cyl-
inder brake reservoir with acleansuction gun.
Fig. 37 Seating Dust Boot
1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER
Fig. 38 CALIPER ADAPTER
1 - CALIPER ASSEMBLY
2 - MOUNTING BOLT
3 - DISC BRAKE ROTOR
DRBRAKES - BASE 5 - 21
DISC BRAKE CALIPERS (Continued)