2004 Dodge RAM 1500 Pickup Brake Service (ONLINE REPAIR MANUALS)

RWAL System

This system prevents rear wheel lock-up by monitoring wheel speed and altering pressure to the rear wheels. The system uses one sensor mounted on the rear differential to determine if the rear wheels are locking up. This system has a "passive" rear wheel control (meaning rear brake pressure during anti-lock braking is provided by the master cylinder). Rear brake fluid application is controlled according to wheel speed, degree of wheel slip and rate of de...

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 required.

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 required, 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 thickness of ...

Master Cylinder

Except Caravan, Town & Country & Voyager

• With engine off, pump brake pedal five times to deplete vacuum in brake booster.
• Siphon fluid from brake reservoir.
• On Wrangler models, remove evaporative canister.
• On PT Cruiser models, remove air cleaner housing, then disconnect power distribution center and position aside.
• On all models, disconnect low fluid switch electrical connector.
• Remove brake lines from master cylinder.
• Remove master cylinder mounting nuts.
• On Durango models with ESP, remove inner fender well, then remove integrated power module (IPM) fasteners and ...

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 ex...

Master Cylinder

Except Caravan, Town & Country & Voyager

The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir is the only serviceable component.

The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. The equalization feature does not affect circuit separation in the event of a front or rear brake fault. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit.

Caravan, Town & Country...

Caravan, Town & Country & Voyager

Refer to for caliper replacement procedures.

Disassemble

• Remove caliper from adapter and rotor as outlined under . Do not disconnect brake hose from caliper. Support caliper at all times to prevent brake hose damage.
• Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place a small block of wood between caliper fingers to prevent piston damage during removal.
• Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any position below one inch of pedal travel to prevent master cy...