1998 DODGE RAM 1500 rear brakes

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8AAudio/Video
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8TNavigation/Telecommunication
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

POSITION INTERPRETATION CODE = DESCRIPTION
4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.
H = 6,001-7,000 lbs.
J = 7,001-8,000 lbs.
K = 8,001-9,000 lbs.
L = 9,001-10,000 lbs.
M = 10,001-14,000 lbs.
W = Buses/Incomplete Vehicles with Hydraulic Brakes
5 Vehicle Line A = Ram Pickup 4X2
U = Ram Pickup 4X4
N = Ram Pickup 4X2 DX Family
6 Series 1 = 1500
2 = 2500
3 = 3500 Less Dual Rear Wheels
4 = 3500 With Dual Rear Wheels
5 = 4000 DX Family
7 Body Style 6 = Conventional Cab/Cab Chassis
8 = Quad Cab Full Rear Doors
8 Engine K = 3.7L 6 cyl. MPI Gasoline
N = 4.7L 8 cyl. MPI Gasoline
D = 5.7L 8 cyl. SMPI Gasoline
6 = 5.9L 6 cyl. Turbo Diesel 24v
C = 5.9L 6 cyl. Turbo Diesel High Output
9 Check Digit 0 through 9 or X
10 Model Year 4 = 2004
11 Plant Location S = Dodge City
G = Saltillo
J = St. Louis (North)
12 thru 17 Vehicle Build Sequence
VEHICLE EMISSION CONTROL
INFORMATION (VECI)
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. DaimlerChrysler permanently
attaches the label in the engine compartment (Fig.
2). The label cannot be removed without defacing
label information and destroying label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
The label also contains an engine vacuum sche-
matic. There are unique labels for vehicles built for
sale in the state of California and the country of
Canada. Canadian labels are written in both the
English and French languages.
The VECI label contains the following:
²Engine family and displacement
²Evaporative family
²Emission control system schematic
²Certification application
²Engine timing specifications (if adjustable)²Idle speeds (if adjustable)
²Spark plug and gap
Fig. 2 VEHICLE EMISSIONS CERTIFICATION
INFORMATION LABEL
1 - VECI LABEL LOCATION
2 - RADIATOR SUPPORT
2 INTRODUCTIONDR
VEHICLE IDENTIFICATION NUMBER (Continued)

(6) Position the hub spacer (Fig. 8) and brake
shield (Fig. 9) on bolts just installed in knuckle.
NOTE: If the vehicle is equipped with a wheel speed
sensor the brake shield must be positioned on the
hub bearing (Fig. 10).
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.NOTE: Position wheel speed sensor wire at the top
of the knuckle if equipped.
(8) Align the bolt holes in the hub bearing flange
with the bolts installed in the knuckle. Then thread
the bolts into the bearing flange far enough to hold
the assembly in place.
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 202 N´m (149 ft. lbs.
(10) Install the washer and axle nut and tighten a
beginning torque of 179 N´m (132 ft. lbs.).
(11) Rotate the axle 5 to 10 times to seat the hub
bearing.
(12) Tighten to a final torque of 356 N´m (263 ft.
lbs.).
(13) Align the axle nut to the next forward cotter
pin hole and install a new cotter pin in the axle nut.
(14) Install the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(15) Install the sensor wire to the steering knuckle
and frame and if equipped. Connect the wheel speed
sensor wire under the hood.
(16) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(17) Remove the support and lower the vehicle.
(18) Apply the brakes several times to seat the
brake shoes and caliper piston. Do not move the vehi-
cle until a firm brake pedal is obtained.
Fig. 8 Hub Spacer
1 - ROTOR HUB BOLTS
2 - HUB SPACER (POSITION FLAT TO REAR)
3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
Fig. 9 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
3 - STEERING KNUCKLE
Fig. 10 Brake Shield With Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - HUB BEARING
3 - SHIELD
DRFRONT - LINK/COIL 2 - 33
HUB / BEARING (Continued)

(1) Through the axle tube use Wrench C-4164 to
adjust each threaded adjuster inward until the differ-
ential bearing free-play is eliminated. Allow some
ring gear backlash approximately 0.25 mm (0.01 in.)
between the ring and pinion gear. Seat the bearing
cups with the procedure described above.
(2) Install dial indicator and position the plunger
against the drive side of a ring gear tooth (Fig. 9).
Measure the backlash at 4 positions, 90 degrees
apart around the ring gear. Locate and mark the
area of minimum backlash.
(3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
measurements will be taken with the same gear
teeth meshed.
(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.076 to 0.102
mm (0.003-0.004 in.) with each adjuster tightened to
14 N´m (10 ft. lbs.). Seat the bearing cups with the
procedure described above.
(5) Tighten the differential bearing cap bolts 136
N´m (100 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N´m (75 ft. lbs.). Seat the bearing cups with the pro-
cedure described above. Continue to tighten the
right-side adjuster and seat bearing cups until the
torque remains constant at 102 N´m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).(8) Continue increasing the torque at the right-
side threaded adjuster until the specified backlash is
obtained.
NOTE: The left-side threaded adjuster torque
should have approximately 102 N´m (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Tighten the left-side threaded adjuster until
102 N´m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(10) Install the threaded adjuster locks and
tighten the lock screws to 10 N´m (90 in. lbs.).
GEAR CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern is correct (Fig. 10). Back-
lash and pinion depth is correct.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
Fig. 10 CORRECT CONTACT PATTERN
DRREAR AXLE - 9 1/4 3 - 87
REAR AXLE - 9 1/4 (Continued)

DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 41).
(6) If rotating torque is less than 41 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Holding Fixture 8136 in vise and set
differential case on fixture (Fig. 42).
(2) Remove pinion gear mate shaft screw.
(3) Remove pinion gear mate shaft.
Fig. 40 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 41 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 42 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
DRREAR AXLE - 9 1/4 3 - 101
DIFFERENTIAL-TRAC-LOK (Continued)

(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.
(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 9).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern correct (Fig. 10). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
11). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 10 CORRECT CONTACT PATTERN
Fig. 11 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 118 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.
(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 9).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern correct (Fig. 10). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
11). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 10 CORRECT CONTACT PATTERN
Fig. 11 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 146 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11 1/2 AA (Continued)

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 45
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING............................5
STANDARD PROCEDURE - PRESSURE
BLEEDING............................5
SPECIAL TOOLS
BASE BRAKES........................5
ADJUSTABLE PEDAL SWITCH
REMOVAL.............................6
INSTALLATION..........................6
ADJUSTABLE PEDAL MOTOR
DESCRIPTION..........................6
REMOVAL.............................7
INSTALLATION..........................7
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART.......8
BASE BRAKE........................10
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING...................10
STANDARD PROCEDURE - ISO FLARING . . 11
REMOVAL
REMOVAL - REAR BRAKE HOSE.........11
REMOVAL - REAR TUBE / HOSE
ASSEMBLY..........................12
REMOVAL - FRONT HOSE..............12
INSTALLATION
INSTALLATION - REAR BRAKE HOSE......12
INSTALLATION - REAR TUBE / HOSE
ASSEMBLY..........................13
INSTALLATION - FRONT BRAKE HOSE....13BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT....................13
REMOVAL - REAR.....................14
INSTALLATION
INSTALLATION - FRONT................16
INSTALLATION - REAR.................16
DISC BRAKE CALIPERS
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL
REMOVAL - FRONT....................17
REMOVAL - REAR.....................17
DISASSEMBLY.........................18
INSPECTION..........................19
ASSEMBLY............................20
INSTALLATION
INSTALLATION - FRONT................21
INSTALLATION - REAR.................21
DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - FRONT....................21
REMOVAL - REAR.....................21
INSTALLATION
INSTALLATION - FRONT................22
INSTALLATION - REAR.................22
DISC BRAKE CALIPER ADAPTER MOUNT
REMOVAL - REAR......................22
INSTALLATION.........................22
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................23
STANDARD PROCEDURE - BRAKE FLUID
LEVEL..............................23
SPECIFICATIONS
BRAKE FLUID........................23
DRBRAKES 5 - 1