Chrysler Full-Size Trucks 1989-1996 Repair Guide

Brake Pads

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CAUTION
Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

REMOVAL & INSTALLATION




WARNING
NEVER replace the pads on one side only! ALWAYS replace pads on both wheels as a set!

Dakota Models

See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Caliper mounting points-Dakota models

Dakota models use a single piston sliding caliper.

  1. Raise and support the front end on jackstands.
  2.  



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Fig. Fig. 2: Remove the caliper from the rotor

  1. Remove the wheels.
  2.  
  3. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  4.  



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Fig. Fig. 3: Remove the outboard shoe spring as shown-Dakota models

  1. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  2.  
  3. Rotate the caliper rearward off the rotor and out from its mount.
  4.  



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Fig. Fig. 4: Remove the outboard pad from the Dakota caliper

  1. Set the caliper on a crate or sturdy box, then remove the inboard and outboard brake pads. The inboard pad has a spring clip that holds it in the caliper. Tilt this pad out at the top to unseat the clip. The outboard pad has a retaining spring that secures it in the caliper. Unseat one spring end and rotate the pad out of the caliper.
  2.  



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Fig. Fig. 5: Unclip and remove the inboard pad from the Dakota's caliper's piston


WARNING
DO NOT depress the brake pedal with the pads removed!

  1. Secure the caliper to a chassis or suspension component with a sturdy wire. Do not let it hang from the hose.
  2.  



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Fig. Fig. 6: Exploded view of the Dakota disc brake components

To install:
  1. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease, or equivalent.
  2.  
  3. Clean the caliper slide pins with brake cleaner or brake fluid. Then apply a light coating of silicone grease to the pins.
  4.  

If there is minor rust or corrosion on the pins, first polish them with a crocus cloth. If they are severely rusted, replace them.

  1. Install the inboard pad and its spring clip.
  2.  
  3. Install the outboard brake pad.
  4.  
  5. Install the caliper over the rotor and seat it flush in its original position.
  6.  
  7. Install the mounting bolts by hand, then tighten them to 38 ft. lbs. (51 Nm).
  8.  
  9. Final tighten the caliper slide pins to 18-26 ft. lbs. (25-35 Nm).
  10.  
  11. Install the wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Pump the brakes several times to seat the pads.
  16.  

Chrysler Sliding Caliper

See Figures 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

The 1989-93 D100/150, W100/150 and Ramcharger use the Chrysler sliding caliper with the 11.75 in. (298.5mm) rotor. The 1989-93 D200/250 and D300/350 and W200/250 with the Dana 44 axle use the Chrysler sliding caliper with a 12.82 in. (325.6mm) rotor.

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the caliper retaining clips and anti-rattle springs.
  6.  
  7. Remove the caliper from the disc by slowly sliding the caliper and brake pad assembly out and away from the disc. Do not damage the flexible brake hose.
  8.  
  9. Drain some of the fluid from the master cylinder.
  10.  
  11. Remove the outboard pad from the caliper by prying between the pad and the caliper fingers. Remove the inboard pad from the caliper support by the same method. DO NOT depress the brake pedal with the pads removed!
  12.  



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Fig. Fig. 7: Rear view of the single piston Chrysler sliding caliper-2WD models

To install:
  1. Push the pistons to the bottom of their bores. This may be done with a large C-clamp or a pair of large pliers by placing a flat metal bar against the pistons and depressing the pistons with a steady force. This operation will displace some of the fluid in the master cylinder.
  2.  



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Fig. Fig. 8: Front view of the single piston Chrysler sliding caliper-2WD models

  1. Slide the new pads into the caliper and caliper support. The ears of the pad should rest on the bridges of the caliper.
  2.  



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Fig. Fig. 9: Remove the retaining clips and anti-rattle springs from the Chrysler single piston caliper-2WD models

  1. Install the caliper on the disc and install the caliper retaining clips, pins and anti-rattle springs. Pump the brake pedal until it is firm.
  2.  



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Fig. Fig. 10: Remove/install the Chrysler single piston caliper assembly



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Fig. Fig. 11: Carefully pry between the outboard pad and caliper to remove the pad from the caliper assembly

  1. Check the fluid level in the master cylinder and add fluid as needed.
  2.  



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Fig. Fig. 12: Remove the inboard pad from the carrier



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Fig. Fig. 13: Exploded view of the Chrysler caliper and brake pad assembly

  1. Install the wheels.
  2.  



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Fig. Fig. 14: Use a large C-clamp to press the caliper's piston back to its original position



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Fig. Fig. 15: Loosen the anti-rattle spring from the caliper



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Fig. Fig. 16: Set all hardware aside in order and in a safe location

  1. Road test the truck. The truck may pull to one side, but the pull should disappear shortly as the pads are seated.
  2.  



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Fig. Fig. 17: Remove the caliper from its carrier



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Fig. Fig. 18: Inspect both pads for damage and wear

Bendix Sliding Caliper Type

See Figures 19, 20, 21, 22, 23, 24, 25, 26 and 27

This brake type is utilized by the W200/250 and W300/350 with the Dana or Spicer 60 axle. These models use a 12.88 in. (327mm) rotor with the caliper.



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Fig. Fig. 19: Details of the Bendix brake assembly-1989-93 models

  1. Remove and discard some of the fluid from the master cylinder without contaminating the contents to avoid overflow later on.
  2.  



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Fig. Fig. 20: Details of the Bendix caliper adapter and steering knuckle

  1. Support the front suspension on jackstands. Remove the wheels.
  2.  



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Fig. Fig. 21: Exploded view of the Bendix caliper and brake pad assembly

  1. Put a large (at least 8 in./203mm) C-clamp over the caliper and use it to push the outer pad in and pull the caliper out. This bottoms the caliper piston in its bore.
  2.  



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Fig. Fig. 22: Use a large C-clamp to bottom the piston in the bore

  1. Remove the key retaining screw. Drive the caliper support key and spring out toward the outside, using a brass drift.
  2.  



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Fig. Fig. 23: Carefully remove the Bendix caliper support key as shown

  1. Push the caliper down and rotate the upper end up and out. Support the caliper, so as not to damage the brake hose.
  2.  



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Fig. Fig. 24: Remove the inboard brake pad from the caliper adaptor

  1. Remove the outer pad from the caliper. You may have to tap it to loosen it. Remove the inner pad, removing the anti-rattle clip from the lower end of the pad.
  2.  



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Fig. Fig. 25: Use a C-clamp to press out the outboard pad

To install:
  1. Thoroughly clean the sliding contact areas on the caliper and adaptor.
  2.  



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Fig. Fig. 26: Install the caliper onto the adapter as shown

  1. Put the new anti-rattle clip on the lower end of the new inner pad. Put the pad and clip in the pad abutment with the clip tab against the abutment and the loop-type spring away from the disc. Compress the clip and slide the upper end of the pad into place.
  2.  



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Fig. Fig. 27: Install the key and spring with a suitable hammer and brass rod

  1. If the caliper piston isn't bottomed, press it in with a C-clamp.
  2.  
  3. The replacement outer pad may differ slightly from the original equipment. Put the outer pad in place and press the tabs into place with your fingers. You can press the tabs in with a C-clamp, but be careful of the lining.
  4.  
  5. Position the caliper on the adaptor by pivoting it around the upper mounting surface. Be careful of the boot.
  6.  
  7. Use a suitable prytool to hold the upper machined surface of the caliper against the support assembly. Drive a new key and spring assembly into place with a plastic mallet. Install the retaining screw and tighten to 12-20 ft. lbs. (16-27 Nm).
  8.  
  9. Replace the wheels and tires and lower the truck to the floor. Fill the master cylinder as specified in Routine Maintenance . Depress the brake pedal firmly several times to seat the pads on the disc. Don't drive until you get a firm pedal.
  10.  

Delco Sliding Caliper

See Figures 28, 29, 30, 31, 32, 33, 34 and 35

The 1994-96 Dakota and Pick-up models use the Delco sliding caliper.

  1. Raise and support the front end on jackstands.
  2.  



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Fig. Fig. 28: Front view of the Delco sliding caliper-1994-96 models

  1. Remove the wheels.
  2.  



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Fig. Fig. 29: Remove/install the caliper once the slide pins are unbolted-1994-96 models

  1. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  2.  



Click image to see an enlarged view

Fig. Fig. 30: Tilt the inboard brake pad to disengage the retaining clip

  1. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  2.  



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Fig. Fig. 31: Disengage one end of the retaining spring, then remove the outboard brake pad

  1. Rotate the caliper rearward off the rotor and out from its mount.
  2.  



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Fig. Fig. 32: Hang the caliper so that its weight is off the line-2WD Pick-up caliper shown; others are similar

  1. Set the caliper on a crate or sturdy box, then remove the inboard and outboard brake pads. The inboard pad has a spring clip that holds it in the caliper. Tilt this pad out at the top to unseat the clip. The outboard pad has a retaining spring that secures it in the caliper. Unseat one spring end and rotate the pad out of the caliper.
  2.  


WARNING
DO NOT depress the brake pedal with the pads removed!

  1. Secure the caliper to a chassis or suspension component with a sturdy wire. Do not let it hang from the hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 33: Mounting bolt lubrication points-1994-96 Pick-up light duty caliper

To install:
  1. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease, or equivalent.
  2.  

If there is minor rust or corrosion on the pins, first polish them with a crocus cloth. If they are severely rusted, replace them.

  1. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111®, or GE 661® silicone grease, or equivalent. (Please refer to illustrations).
  2.  



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Fig. Fig. 34: Mounting bolt lubrication points-1994-96 Pick-up heavy duty caliper

  1. Install the inboard pad and its spring clip.
  2.  
  3. Install the outboard brake pad.
  4.  



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Fig. Fig. 35: Correct brake pad installation in the caliper-Pick-up caliper shown

  1. Install the caliper over the rotor and seat it flush in its original position.
  2.  
  3. Install the mounting bolts by hand, then tighten them to 38 ft. lbs. (51 Nm).
  4.  
  5. Install the wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Pump the brakes several times to seat the pads.
  10.  

INSPECTION



1989-93 Models

Remove the brake pads as described below and measure the thickness of the lining. If the lining at any point on the pad assembly is less than 1 / 16 in. (1.5mm) for light duty brakes or 1 / 32 in. (0.794mm) for heavy duty brakes, thick (above the backing plate or rivets), or there is evidence of the lining being contaminated by brake fluid or oil, replace the brake pad.

1994-96 Models

See Figure 36

Inspect the condition of the outboard pad spring. Replace the spring if bent, distorted or broken.

Inspect the pads. If the lining is worn, cracked or burned, replace the pads. Also if the inboard retainer spring is damaged, replace the shoes.



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Fig. Fig. 36: Brake pad inspection points-Dakota pad shown

Inspect the condition of the shoe tangs. The tang notches are important as they position the shoes in the adapter. The tangs also allow the shoes to slide on the adapter ledge for wear adjustment. Replace the shoes as a set is a tang on either shoe is bent, worn or damaged.

 
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