Dodge RAM TRUCK 1500 1995 Service Manual page 227

BR
DISC BRAKES 5 - 55
MOUNTING
BOLTS
CALIPER
PISTON
SEAL
INBOARD
BRAKESHOE
OUTBOARD
BRAKESHOE
/ j
BUSHINGS
BLEED
SCREW
CALIPER
PISTON
DUST
BOOT
J9405-37
Fig. 24 Caliper Components (80/86mm Caliper)
Inspect condition of the threads in the inlet and
bleed screw ports. Replace the caliper if thread dam­
age is evident. Do not attempt to salvage the threads.
Check the bushings in the caliper mounting bolt
bores. Replace the bushings if worn, cut, or torn.
Bushing condition is important as they keep road
dirt and water from the mounting bolts.
DISC BRAKE CALIPER OVERHAUL AND
REASSEMBLY
(1) Be sure caliper assembly area of workbench is
clean and dry. This is important as dust, dirt, foreign
material, oil, or solvents can damage seals, harm pis­
ton surfaces and contaminate fluid.
(2) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(3) Install new dust boot on piston as follows:
(a) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Then work boot lip into boot
groove at top of piston (Fig. 25).
•(b) Stretch boot rearward as shown to straighten
boot folds. Then move boot forward until folds snap
into place (Fig. 25).
(4) Install new seal on piston. Slide seal onto pis­
ton and seat in groove. Be sure square cut seal is
fully seated and is not twisted.
(5) Install caliper piston. Apply more brake fluid to
piston, seal and bore. Then work caliper piston into
bore. Once piston seal is properly started, press pis­
ton 3/4 of way to bottom of bore by hand or with
hammer handle.
(6) Seat dust boot in caliper with appropriate in­
staller tool (Fig. 26):
• use Installer Tool 6753 on 75mm (1/2 ton) caliper
• CALIPER
PISTON
IN PISTON
GROOVE
^J9405-40
Fig. 25 Installing Dust Boot On Caliper Piston
• use Installer Tool 6754 on 80 mm (3/4 ton) caliper
• use Installer Tool 6755 on 86mm (1 ton) caliper
(7) Finish pressing caliper piston to bottom of bore
after dust boot is seated.