1996 Dodge RAM 1500 Pickup Brake Service (ONLINE REPAIR MANUALS)

Removal

• Raise and support vehicle, then remove tire and wheel assemblies.
• Press caliper piston back into bore using suitable large, flat blade screwdriver, Fig. . Use large C-clamp if additional force is needed.
• Remove caliper mounting bolts with 3/8 hex wrench or socket, Figs. and .
• Rotate caliper rearward off rotor and out of steering knuckle support ledges, Fig. .
• Remove inboard and outboard brake pads, Fig. . Inboard pad has spring clip that holds it in caliper piston. Tilt pad out at top to unseat clip. Outboard pad has retaining spring that holds it in caliper. Unseat one sp...

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...

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...

The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. On vehicles with disc brakes the brake pedal will require more pumping and frequent checking of fluid level in master cylinder during bleeding operation.

Never use brake fluid that has been drained from hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and that the pad assemblies are properly seated. Before driving the vehicle, check brake operation to be sure that a firm pedal has been obtained.

The following procedures may be...

Brake Drums

Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor scor...