1992 Dodge D150 Pickup Brake Service (ONLINE REPAIR MANUALS)

• Raise and support vehicle, then remove wheel.
• Remove caliper as outlined under "Caliper Service." It is not necessary to disconnect brake line from caliper, but caliper must be supported at all times to prevent brake line damage.
• Remove grease cap, cotter pin, nut lock, hub nut, thrust washer and outer wheel bearing, then lift rotor off spindle.
• Reverse procedure to install, noting the following...

• Raise and support vehicle, then remove wheel.
• Remove caliper as outlined under "Caliper Service." It is not necessary to disconnect brake line from caliper, but caliper must be supported at all times to prevent brake line damage.
• Remove grease cap, cotter pin, nut lock, hub nut, thrust washer and outer wheel bearing, then lift rotor off spindle.
• Reverse procedure to install, noting the following...

Removal

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

Installation

Remove approximately ^1/3 of the brake fluid from the reservoir to prevent overflow when pistons are pushed back into their bores.

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

Rear Wheel Anti-Lock (RWAL) Brake System

Refer to "Wiring Diagrams" in "Vehicle Systems" to aid diagnosis

RWAL system malfunctions are indicated by a warning lamp on the instrument cluster. If such a malfunction occurs, proceed as follows:

• Inspect brake fluid level and correct as necessary.
• Visually inspect ABS hydraulic and electrical connections and correct as necessary.
• If hydraulic system leaks or weak or corroded electrical connections are not evident, road test vehicle to inspect vehicle for driveability conditions such as low or spongy pedal, brake pulling or grabbing.
• Ensure parki...

Brake System Bleed

The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module.

Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir.

T...

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 exposure.

• Wear a s...