2003 Dodge RAM 3500 VAN Brake Service (ONLINE REPAIR MANUALS)

Service Brake

Except FWD Models

Self-Adjusting Brakes

These brakes have self-adjusting shoe mechanisms that ensure correct lining to drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward.

Although the brakes are self-adjusting, an initial adjustment is required when the brake shoes have been relined, replaced or when the length of the star wheel adjuster has been changed during some other service operation.

Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the aut...

Front

• 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.
• On 1999 models, remove caliper adapter from steering knuckle.
• On all models, 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:
• Pack wheel bearings with suitable high temperature grease; if inner bearing is removed for packing, replac...

Removal

• Remove caliper assembly as outlined under. "Caliper Service."
• Remove inboard and outboard pads from caliper adapter.
• Remove anti-rattle springs from caliper adapter.

Installation

Remove approximately ^1/4 of the brake fluid from t...

This sliding caliper single piston system uses a one or two piece hub and is actuated by the hydraulic system and disc assembly. Alignment and positioning of the caliper is achieved by two machined guides on the adapter, while caliper retaining clips or machined bolts allow lateral movement of the caliper. Braking force applied onto the outboard pad is transferred to the caliper, while braking force applied onto the inboard pad is transferred d...

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 e...