1990 Dodge W350 Pickup Brake Service (ONLINE REPAIR MANUALS)

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level due to a chemical breakdown during use, and a few precautions will minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposur...

Disassemble

• Remove the vacuum and power steering pump assembly, Fig. .
• Clean gasket from engine gear cover.
• Fabricate a pin, Fig. from an 8 mm hardened drill rod or a grade 8 capscrew.
• Insert the pin into the pump shaft, then screw a M14 X 2 mm threaded capscrew in the shaft against the pin, Fig. .
• Tighten the capscrew against the pin, then remove the gear, eccentric and bearing assembly from the power steering pump shaft.
• If gear or eccentric is not damaged, do not separate them. If damage is present, press the eccentric out of the gear.
• Visually inspect the bearing while rota...

FRONT & REAR SPLIT SYSTEMS

When the brake pedal is depressed, both the primary (front brake) and the secondary (rear brake) master cylinder pistons are moved simultaneously to exert hydraulic fluid pressure on their respective independent hydraulic systems. The fluid displacement of the two master cylinders is proportioned to fulfill the requirements of each of the two independent hydraulic brake systems.

If a failure of a rear (secondary) brake system should occur, initial brake pedal movement causes the unrestricted secondary piston to bottom in the master cylinder bore. Primary...

REMOVAL

• Raise the vehicle and remove front wheels.
• Disconnect and cap flexible brake line, then remove caliper retaining clips and anti-rattle springs, Fig. .
• Remove caliper from disc by slowly sliding caliper assembly out and away from disc. Use some means to support caliper. Do not let caliper hang from hydraulic line.

DISASSEMBLE

• With caliper and pads removed as described previously, place the caliper onto the upper control arm and slowly depress brake pedal, in turn hydraulically pushing piston out of bore.
• Support pedal below first inch of pedal travel to prevent excessive fluid ...

REMOVAL

• Remove caliper assembly as outlined above.
• Remove outboard pad by prying between the pad and the caliper fingers, Fig. , since flanges on outboard pad retain caliper firmly. Caliper should be supported to avoid damage to the flexible brake hose.
• Remove inboard brake pad from the adapter, Fig. .

INSTALLATION

Remove approximately ^{1 /3} of the brake fluid out of the reservoir to prevent overflow when pistons are pushed back into the bore.

• With care, push piston back into bore until bottomed.
• Install new outboard pad in recess of caliper. No freeplay should exist between brake p...

BRAKE LINES & LININGS

Remove one of the front wheels and inspect the brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary.

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective pad is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

BRAKE ROUGHNESS

The most common cause of brake chatter on disc brakes is a variation in thi...