1991 Dodge W350 Pickup Brake Service (ONLINE REPAIR MANUALS)

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...

CHRYSLER

FRONT WHEEL DRIVE MODELS

• Disconnect and plug brake tubes from master cylinder. Cap master cylinder ports.
• Remove master cylinder attaching nuts.
• Remove master cylinder from power brake unit.
• Reverse procedure to install. Master cylinder should be bench bled before installation, using bleeding tubes tool No. C-4546 or equivalent.

RAM RAIDER & RAM 50

• Disconnect the brake tube from the master cylinder.
• On models equipped with manual brakes, remove clevis pin connecting pushrod to brake pedal.
• Remove the attaching bolts from the toe-board or power brake assembly.
• Reverse pro...

EXCESSIVE PEDAL TRAVEL

• Worn brake lining.
• Pad knock back after cornering or rough road travel.
• Piston or pad assembly not properly seated or positioned.
• Air leak or insufficient fluid in system or caliper.
• Loose wheel bearing adjustment.
• Damaged or worn caliper piston seal.
• Improper booster pushrod adjustment.
• Pads out of flat more than .005 inch.
• Rear brake automatic adjusters inoperative.
• Improperly ground rear brake shoe and lining assemblies.

BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING

• Excessive lateral runout of rotor.
• Rotor excessively out of parallel.

EXCESSIVE PEDAL EFFORT

• Frozen or seiz...

FRONT WHEEL DRIVE MODELS

The rear brakes are self-adjusting. An initial adjustment is necessary after the brake shoes have been relined or replaced, or when the length of the star wheel adjuster has been changed during other service operations. To adjust the rear brakes, proceed as follows:

• Raise and support vehicle.
• Remove adjusting hole covers from brake supports.
• Release parking brake and back off adjustment to slacken cable.
• Insert adjusting tool C-3784 or equivalent into star wheel of adjusting screw. Move handle of tool upward until a slight drag is felt.
• Insert a suitable...

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...

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...