1994 Dodge B250 VAN Brake Service (ONLINE REPAIR MANUALS)

• Raise and support vehicle, then remove wheel.
• Remove caliper as outlined under "Caliper Service." It is not necessary to disconnect brake line from caliper, but caliper must be supported at all times to prevent brake line damage.
• Remove grease cap, cotter pin, nut lock, hub nut, thrust washer and outer wheel bearing, then lift rotor off spindle.
• Reverse procedure to install, noting the following...

• Raise and support vehicle, then remove wheel.
• Remove caliper as outlined under "Caliper Service." It is not necessary to disconnect brake line from caliper, but caliper must be supported at all times to prevent brake line damage.
• Remove grease cap, cotter pin, nut lock, hub nut, thrust washer and outer wheel bearing, then lift rotor off spindle.
• Reverse procedure to install, noting the following...

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 necessary.

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 necessary, 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 o...

Removal

• Remove caliper assembly as outlined under "Caliper Service."
• Remove outboard pad by prying between the pad and the caliper fingers, Fig. , as flanges on outboard pad retain caliper firmly. Caliper should be supported to avoid damage to flexible brake hose.
• Remove inboard brake pad from the adapter, Fig. .

Installation

Remove approximately ^1/3 of the brake fluid from the reservoir to prevent overflow when pistons are pushed back into their bores.

• With care, push piston back into bore until bottomed.
• Install new outboard pad in recess of caliper. No free play should exist between...

Excessive Pedal Travel

• Worn brake lining.
• Pad knock back after cornering or rough road travel.
• Piston or pad assembly not properly seated or positioned.
• Air leak or insufficient fluid in system or caliper.
• Loose wheel bearing adjustment.
• Damaged or worn caliper piston seal.
• Improper booster pushrod adjustment.
• Pads out of flat more than .005 inch.
• Rear brake automatic adjusters inoperative.
• Improperly ground rear brake shoe and lining assemblies.

Brake Roughness Or Chatter; Pedal Pumping

• Excessive lateral runout of rotor.
• Rotor excessively out of parallel.

Excessive Pedal Effort

• Frozen or seiz...

This sliding caliper single piston system uses a one or two piece hub and is actuated by the hydraulic system and disc assembly, Fig. . Alignment and positioning of the caliper is achieved by two machined guides on the adapter, while caliper retaining clips allow lateral movement of the caliper, Fig. . Outboard pad flanges are used to position and locate the pad on the caliper fingers, Fig. , while the inboard pad is retained by the adapter, Fig. . Braking force applied onto the outboard pad is transferred to the calip...