2003 Dodge RAM 1500 VAN Brake Service (ONLINE REPAIR MANUALS)

Removal

• Raise and support vehicle, then remove front wheels.
• Disconnect and cap flexible brake line.
• Remove caliper retaining bolts.
• Remove caliper from disc by slowly sliding caliper assembly out and away from disc.

Overhaul

Disassemble

• Drain brake fluid from caliper.
• Clamp a suitable block of wood over one of the pistons.
• Remove piston with several short bursts of low pressure compressed air directed through fluid inlet port.
• Block piston bore with block of wood and clamp, then repeat above procedure for other piston.
• Remove and discard piston dust boots using a suitable pry tool.. Do n...

Service Brake

Except FWD Models

Self-Adjusting Brakes

These brakes have self-adjusting shoe mechanisms that ensure correct lining to drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward.

Although the brakes are self-adjusting, an initial adjustment is required when the brake shoes have been relined, replaced or when the length of the star wheel adjuster has been changed during some other service operation.

Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the aut...

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...

Front

• 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.
• On 1999 models, remove caliper adapter from steering knuckle.
• On all models, 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:
• Pack wheel bearings with suitable high temperature grease; if inner bearing is removed for packing, replac...

This sliding caliper single piston system uses a one or two piece hub and is actuated by the hydraulic system and disc assembly. Alignment and positioning of the caliper is achieved by two machined guides on the adapter, while caliper retaining clips or machined bolts allow lateral movement of the caliper. Braking force applied onto the outboard pad is transferred to the caliper, while braking force applied onto the inboard pad is transferred d...

Master Cylinder

Except Caravan, Town & Country & Voyager

• With engine stopped, pump brake pedal four or five times to deplete vacuum in power booster.
• Disconnect brake lines at master cylinder.
• Remove ground wire from combination valve bracket.
• Remove master cylinder retaining nuts,. Fig. .
• Slide combination valve bracket off cylinder mounting studs. Loosen or disconnect brake lines at rear anti-lock valve and combination valve, if required.
• Remove master cylinder.
• Reverse procedure to install. Tighten master cylinder mounting nuts and fluid line nuts as specified in. Fig. .

Caravan...