Ram B1500, B2500, B3500, 1999-2003

Brake Pads

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CAUTION
Older brake pads may contain asbestos, which has been determined to be 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.



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Fig. Exploded view of a brake caliper-75/80mm Ram shown

Inspection



  1. Pads must be replaced as a set and preferably on both front wheels at the same time.
  2.  
  3. Measure the thickness of both pads and compare to the minimum acceptable limit given in the specifications chart. Replace both pads on both wheels if any one pad is below the limit. State safety inspection limits may differ from these limits and would naturally take precedence if greater (thicker) than the factory values.
  4.  
  5. Replace the pads if they are scored, contaminated with brake fluid or otherwise damaged. Check rotor as well. The perfect brake job would involve new pads and a resurfaced rotor to ensure maximum braking effectiveness and maximum component service life.
  6.  

Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. 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.
  6.  
  7. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  8.  
  9. Rotate the caliper rearward off the rotor and out from its mount.
  10.  
  11. 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 1 spring end and rotate the pad out of the caliper.
  12.  
  13. Secure the caliper to a chassis or suspension component with a sturdy wire. Do not let it hang from the hose.
  14.  

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

  2.  
  3. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111® or GE 661® silicone grease or equivalent.
  4.  
  5. Install the inboard pad and its spring clip.
  6.  
  7. Install the outboard brake pad.
  8.  
  9. Install the caliper over the rotor and seat it until flush in its original position.
  10.  
  11. Install the mounting bolts by hand, then tighten them to 38 ft. lbs. (51 Nm) for 2001-02 models; 24 ft. lbs. (33 Nm) for 2003-05 models.
  12.  
  13. Install the wheels.
  14.  
  15. Lower the vehicle.
  16.  
  17. Pump the brakes several times to seat the pads.
  18.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.

    Click image to see an enlarged view

    Fig. Rear brake caliper assembly in position

  2.  
  3. Compress the piston.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The springs are not interchangeable.



    Caliper pin bolts
     
    Caliper
     
    Inboard and outboard pads
     
    Anti-rattle springs
     

  6.  
  7. Installation is the reverse of removal. Use brake grease on the springs.
  8.  

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. 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.
  6.  
  7. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  8.  
  9. Loosen the bolt that secures the front brake hose fitting bolt in the caliper.
  10.  
  11. Rotate the caliper rearward off the rotor and out from its mount.
  12.  
  13. Remove the front brake hose fitting bolt completely, then remove the caliper with the pads installed as an assembly. Take care not to drip fluid onto the pad surfaces.
  14.  
  15. Cover the open end of the front brake hose fitting to prevent dirt entry.
  16.  

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. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111® or GE 661® silicone grease or equivalent.
  4.  
  5. Install the caliper over the rotor and seat it in its original position until flush.
  6.  
  7. Install the mounting bolts by hand, then tighten them to 24 ft. lbs. (38 Nm).
  8.  
  9. Install the wheels.
  10.  
  11. Lower the vehicle.
  12.  
  13. Pump the brakes several times to seat the pads.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.

    Click image to see an enlarged view

    Fig. Rear brake caliper assembly in position

  2.  
  3. Compress the piston.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The springs are not interchangeable.



    Caliper pin bolts
     
    Caliper
     
    Inboard and outboard pads
     
    Anti-rattle springs
     

  6.  
  7. Installation is the reverse of removal. Use brake grease on the springs.
  8.  

Single-piston calipers of various sizes were used from 1997-99. For the 2000 model year a twin-piston caliper was used.

  1. Clean the area around the master cylinder reservoir and filler cap(s).
  2.  
  3. Remove the filler cap(s) and siphon off about 25 percent of the fluid. This is to prevent overflow as the piston is pushed into the caliper. Fitting new pads will cause a rise in the fluid level.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the wheel.
  8.  
  9. Pry the piston side pad away from the rotor with a tool which won't scratch the rotor surface.
  10.  
  11. Remove the caliper mounting bolts.
  12.  
  13. Remove the caliper and brake pads from the rotor. Use a plastic mallet to tap it free, if necessary.
  14.  
  15. Pry out the outboard brake pad.
  16.  
  17. Remove the inboard shoe by tilting the pad outward until the retainer spring is clear of the caliper piston.
  18.  
  19. Remove the anti-rattle springs, if fitted (2000 models).
  20.  


NOTE
The anti-rattle springs are not interchangeable.

  1. Support the caliper with a wire or twine: Do NOT allow it to hang by the hose.
  2.  


NOTE
Do NOT apply the brake pedal with the caliper off the rotor. Use a soft wedge (such as a piece of wood) to hold the pads apart if the caliper is to be off the rotor for any length of time.

To install:

  1. Clean the caliper and steering knuckle slide surfaces with a wire brush. Then lubricate the surfaces with a thin coat of high temperature grease.
  2.  
  3. On 1997-99 Rams, lubricate the caliper mounting bolts, collars, bushings and bores with silicone grease.
  4.  
  5. Lubricate and install the anti-rattle springs (2000 models).
  6.  
  7. Install the inboard shoe. Be sure the retainer spring is firmly seated in the caliper piston.
  8.  
  9. Insert the outboard shoe in the caliper.
  10.  
  11. Degrease the rotor with a safe solvent.
  12.  
  13. Push the piston(s) in far enough to allow the pads to clear the rotor. This can be done by hand or with a special tool: several types are available.
  14.  
  15. Install the caliper and rotor assembly. Be sure the caliper is seated flush on the mounting arm surfaces.
  16.  
  17. Start the mounting bolts by hand to prevent crossthreading. Tighten the bolts to 38 ft. lbs. (51 Nm) on 1997-99 models, or to 24 ft. lbs. (33 Nm) on 2000 models.
  18.  
  19. Install the wheel.
  20.  
  21. Apply the brake several times to seat the pads.
  22.  
  23. Check the brake fluid level at the master cylinder reservoir and add if necessary.
  24.  



Click image to see an enlarged view

Fig. Caliper mounting on the 2000 Ram



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Fig. Removing the brake caliper bolts-Ram shown



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Fig. If necessary, tap a stuck caliper off the rotor with a plastic mallet



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Fig. Support the caliper with wire or twine-Do NOT let it hang by the brake hose



Click image to see an enlarged view

Fig. Prying out the outboard pad



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Fig. Removing the inboard pad



Click image to see an enlarged view

Fig. Measure the thickness of each pad and compare with the specification given



Click image to see an enlarged view

Fig. Using a special tool to press the piston into the caliper



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Fig. On 1997-99 Rams, lubricate the caliper bushings and bolts with silicone grease



Click image to see an enlarged view

Fig. Mounting bolt lubrication areas on 75mm caliper: 1997-99 Ram



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Fig. Mounting bolt lubrication areas on 80/86mm caliper: 1997-99 Ram



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Fig. Be sure to lubricate the caliper and steering knuckle slide surfaces



Click image to see an enlarged view

Fig. Installing the top anti-rattle spring-2000 Ram



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Fig. Installing the bottom anti-rattle spring-2000 Ram



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Fig. Start the bolts by hand to avoid crossthreading

 
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