1993 DODGE TRUCK torque

5
- 26
BRAKES

Fig. 13 Positioning Gasket On Pump Mounting
Flange
(2) Insert pump assembly upper attaching bolt in
mounting flange and gasket. Use sealer or grease to
hold bolt in place if necessary.
(3) Position pump assembly on engine and install
upper bolt (Fig. 14). Tighten upper bolt only enough
to hold assembly in place at this time. •
Fig. 14 Installing Pump Assembly On Engine (4) Working from under vehicle, install pump as­
sembly lower attaching bolt. Then tighten upper and
lower bolt to 77 N»m (57 ft. lbs.) torque. (5) Position bracket on steering pump inboard
stud. Then install remaining adapter attaching nut
on stud. Tighten nut to 24 N«m (18 ft. lbs.) torque.
(6) Connect oil feed line to vacuum pump connec­
tor. Tighten line fitting securely.
(7) Install oil pressure sender and connect sender

wires.
(8) Connect steering pump pressure and return
lines to pump. Tighten pressure line fitting to 30
N-m (22 ft. lbs.) torque.
(9) Connect vacuum hose to vacuum pump.
(10) Connect battery cables, if removed.
(11) Fill power steering pump reservoir.
(12) Purge air from steering pump lines. Start en­
gine and slowly turn steering wheel left and right to circulate fluid and purge air from system.
(13) Stop engine and top off power steering reser­
voir fluid level.
(14) Start engine and check brake and steering op­
eration. Verify that power brake booster is providing
vacuum assist and firm brake pedal is obtained.
Then verify that steering action is correct. Do this
before moving vehicle.
(4) Clean and lubricate pump shaft with engine

oil.
(5) Install spacers on steering pump studs (Fig.

12).
(6) Install O-ring on adapter (Fig. 11).
(7) Position adapter on pump studs.
(8) Install attaching nuts on outboard stud and on
the two upper pump studs. Do not install nut on
lower, inboard stud at this time. Tighten nuts to 24
N-m (18 ft. lbs.) torque. (9) Install coupling on pump shaft. Be sure cou­
pling is securely engaged in shaft drive tangs. (10) Install vacuum pump on adapter. Rotate drive
gear until tangs on pump shaft engage in coupling.
Verify that pump is seated before installing attach­
ing nuts. (11) Install and tighten vacuum pump attaching

nuts.

VACUUM-STEERING PUMP ASSEMBLY INSTALLATION

(1) Position new gasket on vacuum pump mount­
ing flange (Fig. 13). Use Mopar perfect seal, or sili­
cone adhesive/sealer to hold gasket in place.

•

BRAKES
5 - 29 presses the outboard shoe lining against the opposite
side of the rotor to complete braking action.
The application or release of fluid pressure causes
only a very slight movement of the caliper and pis­
ton. At brake release, the piston and caliper return
to the non-applied position.
The brakeshoes do not retract an appreciable dis­
tance from the rotor. The minimal running clearance
between the lining and rotor provides improved re­ sponse and reduced pedal travel. It also helps in pre­
venting dirt and foreign material from lodging
between the shoe and rotor surfaces.

DISC
BRAKE
LINING WEAR COMPENSATION
Normal lining wear is compensated for by extension
of the caliper piston and by lateral movement of the cal­
iper in the adapter. Piston position is also determined
in part by the square cut piston seal (Fig. 4).
Normal disc brake lining wear will cause the cali­
per piston to extend enough to maintain proper pedal height and brake response. The caliper bore will re­ceive the extra fluid needed to compensate for the ad­
ditional piston extension.
As the piston extends during brake application, the
square-cut seal is deflected outward (Fig. 4). When
brake pressure is released, the seal straightens and
returns to a normal relaxed position. Although the amount of seal movement is quite small, it is enough
to retract the piston to the necessary minimum run­
ning clearance.
As lining wear occurs, the fluid level in the front
brake reservoir will decrease. This is a normal con­ dition and only requires adding enough fluid to re­store proper level. However, when the brakeshoes are
replaced and the caliper pistons bottomed in the

bores,
the added fluid must be compensated for to avoid overfill and overflow. Removing a small
amount of fluid from the front brake reservoir before­
hand will prevent this condition.
PISTON CALIPER
DUST BOOT
RN102

Fig.
4 Caliper
Piston
Seal
Operation

DISC
BRAKE INSPECTION
Inspect the disc brake components whenever the
caliper and brakeshoes are removed during service
operations or routine maintenance. Check condition of the rotor, brakeshoe lining, caliper
and brake hoses. Front wheel bearing adjustment and
condition can also be checked at this time. The bearings
should be repacked and adjusted if necessary.

Brakeshoes
With the caliper and brakeshoes on the vehicle,
check running clearance between the rotor and
brakeshoes. The shoe lining should either be in very light contact with the rotor or have a maximum of
0.127 mm (0.005 in.) running clearance. If clearance
exceeds the stated amount, apply the brakes several
times and recheck clearance. If clearance is still ex­ cessive, either the shoes are severely worn or the cal­
iper piston could be binding in the bore.

Hoses
And Adapter Inspect condition of the brake lines and hoses. Re­
place either front hose if cut, torn, or the reinforcing
fabric is visible. Check condition of the metal brake-
lines.
Replace any line that is badly rusted, leaking
or damaged in any way.
Clean and lubricate the slide surfaces of the caliper
and adapter. Use Mopar high temperature grease for
this purpose. Also verify that the caliper adapter
bolts are secure and tightened to proper torque.
Fluid Level Check the master cylinder fluid level. Maintain
fluid level to the bottom of the indicator rings on the
reservoir. Note that front disc brake fluid level can
be expected to drop slightly as normal lining wear occurs. Use Mopar brake fluid or equivalent meeting SAE and DOT standards J1703 and DOT 3. Use
clean brake fluid from a sealed container only.

Rotors
Check the rotor surfaces for excessive wear, discol­
oration, scoring, rust, scale, or cracks. Also look for
damaged or severely rusted ventilating segments. If
pedal pulsation was experienced, check wheel bear­ ing adjustment and condition. If the bearings are OK, also check rotor runout and thickness variation.

DISC
BRAKESHOE
REMOVAL
(1) If front brakeshoes are to be replaced, remove
approximately 1/3 of fluid from master cylinder front
brake reservoir with suction gun. (2) Raise and support vehicle.
(3) Remove front wheels.
(4) Press caliper pistons to bottom of bore with
large C-clamp. Position clamp screw on outboard
brakeshoe and position clamp frame on rear of cali­
per. (5) Remove bolts securing caliper retainer clips to
caliper. Then remove clips and anti-rattle springs (Fig. 5).

•

BRAKES
5 - 31 board lining. Also check condition of the caliper pis­
ton dust boot. If leakage is evident or if the boot is
cut, torn, or damaged in any way, it will be neces­sary to overhaul the caliper.
Remove the O-ring from the caliper adapter and clean
the slide surfaces of the adapter and the machined ways on the caliper with a wire brush and sandpaper.

DISC
BRAKESHOE
INSTALLATION
(1) Install inboard brakeshoe in adapter (Fig. 8).
(2) If new brakeshoes are being installed, remove
protective paper from noise suppression gasket on outboard shoe. (3) Install and adjust outboard brakeshoe in cali­
per as follows: (a) Check vertical movement of outboard shoe in
caliper. Shoe should fit tightly and not exhibit ver­
tical movement (free play). Flange must also fit
tightly on caliper finger to eliminate free play and
prevent shoe rattle (Fig. 9). (b) If free play is evident, remove shoe from cal­
iper. (c) Bend shoe retaining flange and trial fit shoe
in caliper. Continue bending flange until shoe is
light interference fit in caliper (Fig. 10). (d) Reinstall outboard brakeshoe in caliper. If
shoe is difficult to install, use C-clamp to seat shoe
(Fig. 11).

OUTBOARD SHOE MACHINED
Fig.
9 Outboard
Brakeshoe
Positioned
On Caliper
Finger

(4) Lubricate slide surfaces of caliper mounting
adapter and machined ways on caliper with Mopar
high temperature, or multi-mileage grease.
(5) Install O-ring in adapter, if removed.
(6) Carefully install caliper over rotor and into
adapter. Do not displace or damage the piston dust boot when installing the caliper.
Fig. 10
Adjusting Outboard
Brakeshoe
Retaining

Flange
Fig.
11 Seating Outboard
Brakeshoe

(7) Align caliper in adapter and install caliper re­
tainer clips and anti-rattle springs (Fig. 5). Tighten
retainer screws to 20 N«m (180 in. lbs.) torque.
(8) Install wheels and lower vehicle.
(9) Top off master cylinder fluid level. (10) Apply brakes several times to seat caliper pis­
tons and brakeshoes and obtain firm pedal. Do this
before moving vehicle.

CALIPER
REMOVAL
(1) Raise vehicle and remove front wheels.
(2) If caliper will only be removed for shoe replace­
ment or access to other component, press caliper pis­
ton to bottom of bore with large C-clamp. (3) Remove caliper retainer clips and anti-rattle
springs. (4) Disconnect brake hose fitting at caliper. (5) Remove caliper from rotor.
(6) Remove brakeshoes from caliper and adapter.

5
- 34
BRAKES

•
boot
>TALLir TOOL
Fig.
19 Seating
Piston
Dust
Boot

(6) Install caliper over rotor and into adapter.
(7) Align caliper in adapter and install caliper re­
tainer clips and anti-rattle springs. Tighten retainer clip screws to 20 N*m (180 in. lbs.) torque.
(8) Connect brake hose to caliper. Tighten fitting
bolt to 47 N»m (35 ft. lbs.) torque. Be sure hose is clear of chassis and suspension components and
use new seal washers to secure hose fitting to caliper. Do not reuse old washers.
(9) Fill master cylinder with Mopar brake fluid or
equivalent meeting SAE and DOT standards J1703 and DOT 3.
(10) Bleed brakes. Refer to procedure in Service
And Adjustments section.
(11) Install wheels and lower vehicle.
(12) Apply brakes several times to seat caliper pis­
tons and brakeshoes. Be sure firm pedal is obtained
before moving vehicle.

ROTOR REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove caliper assembly. Do not allow brake
hose to support caliper. Support caliper on stool, or suspend caliper with wire attached to nearby body or
suspension component. (4) Remove grease cap, cotter pin, nut lock, adjust­
ing nut, thrust washer and outer wheel bearing. (5) Remove rotor from spindle.
(6) Remove rotor shield and seal if either is to be
serviced.
ROTOR
INSPECTION AND
SERVICE

rotor condition The rotor braking surfaces should not be refinished
unless actually necessary. Light surface rust and scale can be removed in a lathe equipped with dual
sanding discs.
Rotor surfaces can be restored by machining in a
disc brake lathe if surface scoring and wear are light.
The rotor should be replaced if:
• severely scored
• tapered
• has hard spots
• is cracked
• too thin • machining would cause rotor thickness to fall be­
low minimum thickness requirements Check rotor lateral runout and thickness variation
if pedal pulsation or an occasional low pedal condi­
tion was experienced. Measure runout with a dial in­ dicator. Measure thickness with a micrometer at a
minimum of four points around the braking surfaces.

CHECKING
ROTOR
MINIMUM
THICKNESS
Measure rotor thickness at the center of the brake-
shoe contact surface. Replace the rotor if it is worn
below minimum thickness, or if refinishing would re­ duce thickness below the allowable minimum. Rotor
minimum thickness is usually specified on the rotor
hub (Fig. 20).
Fig.
20 Typical Location Of Rotor
Minimum

Thickness
Limit
ROTOR RUNOUT Check rotor lateral runout with Dial Indicator
C-3339 as shown in the top view (Fig. 21). Excessive

BRAKES
5 - 39
DISC BRAKE LINING WEAR COMPENSATION
Normal lining wear is compensated for by exten­
sion of the caliper piston and by lateral movement of
the caliper in the adapter. Piston position is also de­ termined in part by the square cut piston seal (Fig.
4).

Normal disc brake lining wear will cause the cali­
per piston to extend enough to maintain proper pedal height and brake response. The caliper bore will re­ceive the extra fluid needed to compensate for the ad­
ditional piston extension.
As the piston extends during brake application, the
square-cut seal is deflected outward (Fig. 4). When
brake pressure is released, the seal straightens and returns to a normal relaxed position. Although the amount of seal movement is quite small, it is enough
to retract the piston to the necessary minimum run­ ning clearance. Fluid level in the front brake reservoir will de­
crease as lining wear occurs, the. This is a normal
condition and only requires adding enough fluid to
restore proper level. However, when the brakeshoes are replaced and the caliper pistons bottomed in the

bores,
the added fluid must be compensated for. This is necessary to avoid overfill and overflow. Removing a small amount of fluid from the front brake reser­
voir beforehand will prevent this condition.

Fig.
4 Caliper
Piston
Seal
Operation

DISC
BRAKE INSPECTION
Inspect the disc brake components whenever the
caliper and brakeshoes are removed during service
operations or routine maintenance. Check condition of the rotor, brakeshoe lining, cal­
iper and brake hoses. Front wheel bearing adjust­
ment and condition can also be checked at this time.
The bearings should be repacked and adjusted if nec­ essary.

Brakeshoes
With the caliper and brakeshoes on the vehicle,
check running clearance between the rotor and
brakeshoes. The shoe lining should either be in very light contact with the rotor or a maximum of 0.127
mm (0.005 in.) running clearance. If clearance ex­ceeds the stated amount, apply the brakes several times and recheck clearance. If clearance is still ex­
cessive, either the shoes are severely worn or the cal­
iper piston could be binding in the bore.

Hoses
And Adapter Inspect condition of the brake lines and hoses. Re­
place either front hose if cut, torn, or the reinforcing
fabric is visible. Check condition of the metal brake-
lines.
Replace any line that is badly rusted, leaking
or damaged in any way.
Clean and lubricate the adapter slide surfaces. Use
Mopar multi-mileage or high temperature grease for
this purpose. Also verify that the caliper adapter
bolts are secure and tightened to proper torque.
Fluid Level Check the master cylinder fluid level. Maintain
fluid level to the bottom of the indicator rings on the
reservoir. Note that front brake fluid level can be ex­
pected to drop slightly as normal lining wear occurs.
Use Mopar brake fluid or equivalent meeting SAE and DOT standards J1703 and DOT 3. Use clean
brake fluid from a sealed container only.

Rotors
Check rotor surfaces for excessive wear, discolora­
tion, scoring, rust, scale, or cracks. Also look for damaged or severely rusted ventilating segments. If
pedal pulsation was experienced, check wheel bear­ ing adjustment and condition. If the bearings are OK, also check rotor runout and thickness variation.

DISC
BRAKESHOE REMOVAL
(1) Remove approximately 1/3 of fluid from master
cylinder front brake reservoir with a suction gun. (2) Raise and support vehicle.
(3) Remove wheel and tire assemblies.
(4) Press caliper pistons to bottom of bore with
large C-clamp (Fig. 5). Position clamp screw on out­
board shoe and clamp frame or rear of caliper hous­ ing. (5) Remove support key retaining screw (Fig. 6).
(6) Remove caliper support key and spring. Use
pin punch or drift to tap key out of caliper (Fig. 7). (7) Lift caliper out of adapter. (8) Remove outboard shoe from caliper (Fig. 8).
(9) Secure caliper to convenient chassis component
with wire. Do not allow brake hose to support caliper weight. (10) Remove inboard shoe and anti-rattle spring
from caliper adapter (Fig. 9). Note position of spring
for installation reference.
CLEANING AND INSPECTION Inspect the shoe lining for wear. Replace riveted
shoes if the lining is worn to within 1.5 mm (1/16 in.)
of the rivet heads. Replace bonded lining if thickness is 3 mm (3/16 in.) or less.

•

BRAKES
5 - 41

Fig.
9 Removing/Installing Inboard
Brakeshoe

Fig.
10 Seating Outboard
Brakeshoe
In Caliper (4) Seat caliper in adapter.
(5) Place support spring on support key. Then in­
sert spring and key between caliper and adapter.
(6) Tap support key and spring into place with pin
punch or drift (Fig. 12). (7) Align notch in support key with screw hole in
caliper.
(8) Install support key retaining screw. Tighten
screw to 20 N»m (15 ft. lbs.) torque. Be sure shoul­
der on screw is fully seated in support key
notch.
(9) Install wheel and tire assembly and lower vehi­

cle.
(10) Top off master cylinder fluid level.
(11) Pump brake pedal to seat shoes and restore
normal pedal height. Do not move vehicle until firm
pedal is obtained.
CALIPER

Fig.
11 Caliper
Installation
CALIPER

Fig.
12 Installing
Support
Key And
Spring

CALIPER
OVERHAUL
CALIPER REMOVAL
(1) Raise vehicle and support on hoist or jack-
stands.
(2) Remove wheel and tire assemblies.
(3) Clean brake hose and tubing connections at
calipers and brake hoses.
(4) Remove screw retaining caliper support key
and spring and tap support key and spring out with
a drift or pin punch.
(5) Remove calipers and brakeshoes from adapters (6) Disconnect caliper brake hoses at frame brack­
ets and remove calipers. (7) Cover brake lines to prevent dirt entry.

•

BRAKES
5 - 43
CAMPER
ASSEMBLY
(1) Mount caliper in vise equipped with protective

jaws.
Do not overtighten vise. Excessive pressure could cause bore distortion and piston binding. (2) Lubricate new piston seal and piston bore with
fresh brake fluid. (3) Install new piston seal in bore groove (Fig. 15).
Position seal in one area of groove and gently work it around and into remainder of groove until seated. Be
sure seal is not twisted or rolled over.

Fig.
15 Installing Caliper
Piston
Seal

(4) Lubricate new dust boot with fresh brake fluid
and install it in caliper (Fig. 16). Work boot into
groove with fingers. Boot will seem larger than
groove diameter at first but will snap into place
when properly positioned.
(5) Plug fluid inlet port and install bleeder screw. (6) Coat caliper piston with brake fluid.
(7) Start piston into dust boot and bore (Fig. 16).
Spread dust boot with fingers. Then work piston
through boot and into bore. Air trapped below piston
will force boot around it and into groove as piston is installed.
(8) Remove plug from inlet port and loosen bleeder
screw.
(9) Carefully press piston into bore with turning
motion until fully bottomed. Apply force uniformly to avoid cocking piston (Fig. 16).
(10) Seat dust boot with suitable size installer tool
if necessary.

CALIPER
INSTALLATION
(1) Install brakeshoes in caliper and adapter.
Fig.
16 Installing Caliper
Piston

(2) Connect brake hose to brake line on frame
bracket. Tighten hose fitting to 13-20 N«m (115-175 in. lbs.) torque.
(3) Connect brake hose to caliper. Use new seal
washers when connecting fitting to caliper. Do not
tighten hose fitting at this time.
(4) Lubricate caliper and adapter slide surfaces
with Mopar high temperature grease, or an equiva­ lent grease.
(5) Install and secure caliper in adapter.
(6) Fill master cylinder and bleed brakes.
(7) Install wheel and tire assemblies and lower ve­
hicle.

ROTOR INSPECTION AND
SERVICE

ROTOR
CONDITION
Rotor condition and tolerances can be checked with
the rotor mounted on the axle. However, wheel bear­ ing end play should be reduced to zero before check­
ing lateral runout.
The rotor braking surfaces should not be machined
unless actually necessary. Light surface rust and scale can be removed in a lathe equipped with dual
sanding discs.
Worn, or scored rotor surfaces can be restored by
machining in a disc brake lathe but only if surface scoring and wear are light.
The rotor should be replaced if:
• severely scored
• tapered
• has hard spots
• cracked
• warped
• too thin
• machining would cause rotor thickness to fall be­
low minimum thickness requirements

•

BRAKES
5 - 45 multaneously with dual cutter heads. Equipment ca­
pable of machining only one side at a time will
produce a tapered rotor. The lathe should also be equipped with a grinder
attachment or dual sanding discs for final cleanup or
light refinishing.
If the rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
the rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.

CAUTION:
Do not refinish a rotor if
machining

would
cause
the rotor to
fall
below minimum allow­
able
thickness.

ROTOR REMOVAL
(1) Raise and support front of vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove support key retaining screw (Fig. 6).
(4) Remove caliper support key and spring with
pin punch or drift (Fig. 19).

Fig.
19
Removing
Caliper
Support
Key And
Spring
(5) Remove caliper and brakeshoes from adapter.
Do not allow brake hose to support caliper
weight. Support caliper on stool, or secure cali­
per to nearby frame or chassis component with
wire.
(6) Remove hub cap. (7) Remove drive flange snap ring with Tool
C-4020 (Fig. 20).
(8) Remove flange nuts and lock washers and re­
move drive flange. Discard the flange gasket.
(9) Straighten tang on lock ring. (10) Loosen outer locknut and adjusting nut with
Tool DD-1241-JD (Fig. 19). Then remove outer lock- nut, lock ring, inner adjusting nut and outer bearing. (11) Remove hub and rotor from spindle.
Fig.
20
Removing
Drive Flange
Snap
Ring

(12) Remove seal and inner bearing from hub if
bearing or seal requires service.
(13) If wheel bearing races require service, remove
them with suitable remover tools or with brass drift. (14) Clean rotor and hub and wheel bearings in
solvent.

ROTOR
INSTALLATION
(1) Repack wheel bearings and coat spindle with
Mopar high temperature bearing grease. (2) Install new bearing races, bearings and seals in
hubs if necessary. (3) Install hub on spindle and install outer bearing
and inner adjusting nut. (4) Tighten adjusting nut to 68 Nrni (50 ft. lbs.)
with Special Tools DD-1241-JD and C-3952 to seat
bearings. (5) Adjust wheel bearings as follows: (a) Back off adjusting nut.
(b) Retighten adjusting nut to 54 N*m (40 ft. lbs.)
while rotating hub and rotor. (c) Back off adjusting nut approximately 135 to
150 degrees. (d) Install lock ring and locknut.
(6) Tighten lock nut to a minimum of 88 N»m (65
ft. lbs.). Bearing end play should be 0.025 - 0.25 mm (0.001 - 0.010 in.). (7) Bend one tang of lock ring over adjusting nut
and another tang over locknut to secure them. (8) Install new gasket on hub and install drive
flange, lock washers and nuts. Tighten nuts to 41 - 54 N«m (30 - 40 ft. lbs.). (9) Install flange snap ring with Tool C-4020.
(10) Install hub cap.
(11) Install caliper and brakeshoes. Tighten sup­
port retaining screw to 20 Nnn (15 ft. lbs.) torque. (12) Install wheel and tire assembly and lower ve­
hicle.