Chrysler RAM TRUCK 2500 1994 Service Manual page 212

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
• use Installer Tool 6754 on 80 mm (3/4 ton) caliper
• use Installer Tool 6755 on 86mm (1 ton) caliper
J94Q5-41
Fig. 26 Seating Dust Boot In Caliper
(7) Finish pressing caliper piston to bottom of bore
after dust boot is seated.
(8) Lubricate caliper mounting bolts, collars, bush­
ings and bores with Dow 111, or GE 661 silicone
grease (Figs. 16 and 17).
(9) Install bushings, seals, boots and mounting
bolts i n caliper (Figs. 23 and 24).
(10) Install but do not fully tighten caliper bleed
screw.
(11) Install inboard brakeshoe i n caliper. Be sure
brakeshoe spring clip is centered and seated i n cali­
per piston (Fig. 27).
(12) Install outboard brakeshoe i n caliper (Fig. 28).
Align shoe and retaining spring in caliper. Then push
shoe downward into place. Be sure spring ends are
correctly seated i n caliper dimples.
DISC BRAKE CALIPER INSTALLATION
(1) Clean caliper and steering knuckle slide sur­
faces with wire brush (Fig. 16). Then apply coat of
Mopar multi-mileage grease, or Dow/GE silicone
grease to slide surfaces.
(2) Install caliper over rotor and seat i t on steering
knuckle mounting arms.
SPRING
CUP
(IN PISTON)
INBOARD
BRAKESHOE
J9405-42
Fig. 27 Inboard Brakeshoe Installation
SHOE
RETAINING
SPRING
OUTBOARD
BRAKESHOE
J9405-43
Fig. 28 Outboard Brakeshoe Installation
(3) Start caliper mounting bolts by hand to avoid
cross threading. Then tighten mounting bolts to 51
N-m (38 ft.lbs.) torque.
(4) Connect brake hose to caliper (Figs. 29 and 30).
Be sure brake hose fitting is correctly seated
against locating shoulder on caliper before
tightening fitting bolt.
CAUTION: B e very sure the front brake hose is not
twisted, or kinked. Also be sure the hose is cor­
rectly routed and clear of adjacent c h a s s i s and s u s ­
pension components. This is important a s hose
damage will result if it is twisted or incorrectly
routed.
(5) Fill and bleed brake system. Refer to procedure
in appropriate antilock brake section.
(6) Install wheel and tire assemblies and lower ve­
hicle.