2003 Dodge RAM 3500 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...

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...

These self contained vacuum hydraulic power braking units are of the vacuum suspended type. They use engine intake manifold vacuum or a vacuum pump along with atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, with integral vacuum power diaphragms, controls the degree of brake application or release depending on amount of foot pressure applied to...

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...

Pedal Falls Away

• System leak at brake line, fitting, hose or caliper/wheel cylinder.
• Internal leakage in master cylinder caused by worn or damaged piston cups.
• Internal leak in ABS or RWAL system.

Low Pedal

• Worn brake linings.
• Worn drums or rotors.
• Rear brakes out of adjustment.

Spongy Pedal

• Air in hydraulic system.
• Thin brake drums.
• Substandard brake lines and hoses.

Hard Pedal Or High Pedal Effort

• Linings that are water soaked, contaminated or glazed.
• Defective power booster or check valve.

Pedal Pulsation

• Disc brake rotors have excessive lateral runout or thickness variation.
• Out of round bra...

These self contained vacuum hydraulic power braking units are of the vacuum suspended type. They use engine intake manifold vacuum or a vacuum pump along with atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, with integral vacuum power diaphragms, controls the degree of brake application or release depending on amount of foot pressure applied to...