Dodge ram truck 3500 1996 Service Manual page 224

5 - 40 BRAKES -
DISASSEMBLY AND ASSEMBLY {Continued)
B R
M O U N T I N G
BOLTS
BLEED
SCREW
CALIPER
PISTON
SEAL .
INBOARD
BRAKESHOE
OUTBOARD
BRAKESHOE
CALIPER
PISTON
DUST
SOOT
J9405-37
Fig. 86 Caliper Components (80/86mm Caliper)
CAUTION: Never hone the caliper piston bore, or
use any kind of abrasive material on the piston sur­
face. Honing will result in an oversize bore and
abrasives will damage the piston coating. Either of
these practices will result in piston bind and even­
tual seizure.
(4) Inspect condition of the threads in the inlet
and bleed screw ports. Replace the caliper i f thread
damage is evident. Do not attempt to salvage the
threads.
(5) Check the bushings i n the caliper mounting
bolt bores. Replace the bushings i f worn, cut, or torn.
(6) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(7) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Install boot on piston and work
boot lip into the groove at the top of piston (Fig. 87).
(8) Stretch boot rearward to straighten boot folds,
then move boot forward until folds snap into place
(Fig. 87).
(9) Install new piston seal into caliper bore.Be
sure square cut seal is fully seated and is not
twisted.
(10) Install piston into caliper bore. Once piston is
started into the piston seal, press piston 3/4 of way
down into the caliper bore by hand or with hammer
handle.
(11) Seat dust boot in caliper with installer (Fig.
88):
' • 1/2 ton 75mm caliper: Installer 6753
• 3/4 ton 80 mm caliper: Installer 6754
• 1 ton 86mm caliper: Installer 6755
• CALIPER
PISTON
BOOT UP
IN PISTON"
GROOVE "
^ J 9 4 0 5 - 4 0
Fig. 87 installing Dust Boot
(12.) Press piston to the bottom of the caliper bore.