Dodge ram truck 3500 1996 Service Manual page 200

5 - 16 BRAKES B R
S E R V I C E P R O C E D U R E S ( C o n t i n u e d )
J8905-70
Fig. 18 Rotor Refinishing
BRAKE DRUM MACHINING
The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim­
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen­
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface Is stamped or cast into the drum,
outer edge. Always replace the drum i f machining
would cause drum diameter to exceed the size limit
indicated on the drum.
BRAKE LINE
Mopar preformed metal brake line is recommended
and preferred for all repairs. However, double-wall
steel line can be used for emergency repair when fac­
tory replacement parts are not readily available.
Special, heavy duty tube bending and flaring
equipment is required to prepare double wall brake
line. Special bending tools are needed to avoid kink­
ing or twisting metal brake line. I n addition, special
flaring tools are needed to provide the Inverted-type,
double flare required on metal brake lines.
FLARING PROCEDURE
(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on section of tube
to be repaired.
(4) Insert tube In flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch In gauge that matches
tube diameter.
(7) Squeeze flaring tool jaws to lock tubing in
place.
(8) insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar­
ing screw In recess of compression disc (Fig. 19).
(9) Tighten tool handle until plug gauge is seated
on jaws of flaring tool. This will start the inverted
flare.
(10) Remove the plug gauge and complete the
inverted flare.
(11) Remove the flaring tools and verify that the
inverted flare is correct.
R E M O V A L A N D I N S T A L L A T I O N
STOP LAMP SWITCH
REMOVAL
(1) Remove knee bolster for access to stop lamp
switch and pedal.
(2) Disconnect switch harness (Fig. 20).
(3) Press and hold brake pedal in applied position.
(4) Rotate switch counterclockwise about 30° to
align switch lock tab with notch in bracket.