1999 DODGE RAM brake light

SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not

NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION








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Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.









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BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION









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Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake

system which DOES NOT affect the rubber parts, the required
service is to flush and fill with the correct brake fluid.
(Code B)
( 2) - This condition may indicate contaminated brake fluid.









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BRAKE FRICTION MATERIAL
See FRICTION MATERIAL .
BRAKE PADS
See FRICTION MATERIAL .
BRAKE PEDALS
BRAKE PEDAL INSPECTION








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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .... Require replacement of pedal
pad.
Pedal pad worn .......... 1 ............ Suggest replacement.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









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BRAKE SHOES
See FRICTION MATERIAL .
BRAKE SHOE HARDWARE
See also SELF-ADJUSTING SYSTEMS .
BRAKE SHOE HARDWARE INSPECTION









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Condition Code Procedure
Broken .................. A ............ Require replacement.
Distorted ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Surfaces rust-pitted .... 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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BRAKE STOPLIGHT SWITCHES
BRAKE STOPLIGHT INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.

specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.









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STEEL BRAKE LINES
STEEL BRAKE LINE INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.









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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.

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Application psi (kg/cm)
All Models ....................................... 10-15 (1.06-1.41)\









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NOTE: When bleeding disc brakes, air may tend to cling to caliper
walls. Lightly tap caliper while bleeding to aid in removal
of air.
Manual Bleeding
1) Fill master cylinder. Install bleeder hose on first
bleeder valve to be serviced. See BLEEDING SEQUENCE table. Submerge
other end of hose in clean glass jar partially filled with clean brake
fluid.
NOTE: When bleeding brake system manually, ensure bleeder valve is
closed when brake pedal is released.
2) Open bleeder valve 3/4-1 turn. Depress brake pedal slowly
through full travel. Close bleeder valve. Release pedal. Repeat
procedure until fluid flow is free of air bubbles.
ADJUSTMENTS
PARKING BRAKE
1) Release parking brake, and loosen cable adjusting nut to
allow slack in cable. Adjust rear brakes. Tighten cable adjusting nut
until a slight drag is felt while rotating rear wheels.
2) Loosen cable adjusting nut until both rear wheels can be
rotated freely. Back off adjusting nut an additional 2 turns. Apply
and release parking brake several times, checking for free rotation at
rear wheels.
REAR BRAKE SHOES
1) Raise and support vehicle. Ensure parking brake lever is
fully released. Back off parking brake cable adjustment to ensure
cable has slack. Remove adjusting hole cover.
2) Using a brake adjuster, expand brake shoes until slight
drag is felt when wheel assembly is rotated. Using thin screwdriver,
hold automatic adjusting lever away from adjustment star wheel.
3) Back off adjustment star wheel until wheel assembly
rotates freely and brake shoe drag is eliminated. Repeat adjustment
for remaining wheels. Adjustment must be equal at all wheels. Replace
adjusting hole covers. Adjust parking brake. See PARKING BRAKE.
STOPLIGHT SWITCH
Stoplight switch is attached to brake pedal support. Push
stoplight switch through clip in mounting bracket until switch seats
in bracket. Pull brake pedal backward as far as pedal will travel.
Brake pedal will ratchet stoplight switch to correct position. Verify
full brake pedal return, and that stoplights glow when brake pedal is
applied.
TESTING
POWER BRAKE BOOSTER FUNCTIONAL TEST

1) Start engine, and check booster vacuum hose connections. A
hissing noise indicates a vacuum leak. Repair any vacuum leaks before
proceeding. Stop engine, and shift transmission into Neutral. Pump
brake pedal until all vacuum reserve in booster is depleted.
2) Hold brake pedal under light pressure. If pedal does not
hold firm and falls away, master cylinder may be faulty. Bleed system
using appropriate method, and repeat step 1). See BLEEDING PROCEDURES
under BLEEDING BRAKE SYSTEM.
3) If pedal still does not hold firm, master cylinder is
faulty. If pedal holds firm, start engine and observe pedal height. If
pedal height change is not apparent, power booster or vacuum check
valve is faulty. Install good check valve, and repeat steps 1) and 2).\
If pedal falls away slightly under light pressure and then holds firm,
go to next step .
4) Start engine. Release brake pedal. Increase engine speed
to 1500 RPM. Close throttle and immediately turn off ignition. Wait at
least 90 seconds, and try brake action again. Booster should provide 2
or more vacuum assisted pedal applications. If vacuum assist is not
provided, perform booster and check valve vacuum tests.
POWER BRAKE BOOSTER VACUUM TEST
Connect vacuum gauge to booster check valve using "T"
fitting. Start engine, and run at idle speed for one minute. Clamp
hose shut between vacuum source and check valve. Stop engine, and
observe vacuum gauge. If vacuum drops more than one in. Hg within 15
seconds, booster diaphragm or check valve is faulty.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect vacuum hose from check valve. Remove check valve
and valve seal from booster. Use a hand-operated vacuum pump for
testing. Apply 15-20 in. Hg at large end of check valve. Vacuum should
hold steady. If gauge on pump indicates vacuum loss, check valve is
faulty and should be replaced.
COMBINATION VALVE METERING VALVE TEST
Metering valve operation can be checked visually with aid of
an assistant. While an assistant applies and releases brake pedal,
observe metering valve stem. If valve is operating correctly, stem
will extend slightly when brakes are applied, and contract when brakes
are released. If valve is faulty, replace combination valve assembly.
COMBINATION VALVE PRESSURE DIFFERENTIAL SWITCH TEST
1) Using an assistant, apply brake pedal. Observe brake
warning light. Raise and support vehicle, and connect a bleed hose to
one rear wheel cylinder. Submerge other end of hose into container
partially filled with brake fluid. Have assistant press and hold brake
pedal down while observing brake warning light. Open bleeder screw. If
warning light glows, switch is operating properly.
2) If warning light fails to glow, check circuit fuse, bulb
and wiring. Repair as necessary. Repeat step 1). If warning light
fails to glow, check brakelight, parking brake switches and related
wiring. Repair as necessary. Repeat step 1). If warning light fails to
glow, pressure differential switch is faulty. Replace combination
valve assembly, and bleed brake system. Verify proper valve operation.
REMOVAL & INSTALLATION

pads at this time. On models with removable hub, install hub on rotor.
Install wheel and tire assembly. Tighten lug nuts so they are snug,
but DO NOT tighten to final torque specifications.
3) While rotating wheel, tighten adjuster nut sufficiently to
seat bearing. Loosen nut and retighten while still rotating wheel.
Back off adjuster nut to completely release bearing preload torque.
Ensure endplay of .001-.003" (.025-.076 mm). Install lock nut and NEW
cotter pin. If necessary, tighten lock nut slightly to align cotter
pin hole. Install grease cap. Tighten caliper bolts and lug nuts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse remove procedure.
Removal (Ram Pickup With 8 Studs)
1) Raise and support vehicle. Remove wheel. Remove hub
extension, if equipped. Remove brake caliper. Support caliper aside.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove cotter
pin from rotor hub nut. Remove nut. Disconnect ABS wheel speed sensor
wire (if equipped), and remove from frame and steering knuckle. Remove\
bolts securing hub to steering knuckle from inboard side of steering
knuckle. Remove rotor and hub assembly.
Installation
1) Apply anti-seize compound to drive shaft splines. Replace
grease seal in steering knuckle, if necessary. Insert 2 rearmost top
and bottom rotor hub bolts in steering knuckle so they extend through
back of knuckle. Install hub spacer, ensuring flat on space is
positioned to rear. Use chassis grease to hold spacer in position, if
necessary.
NOTE: If equipped with wheel speed sensor, brake shield must be
positioned on hub bearing, and sensor wire must be at top of
knuckle.
2) Align rotor hub with drive shaft and install hub assembly.
Align bolt holes in hub flange with bolts previously installed. Start
nuts on flange bolts sufficiently to hold assembly in place. Install
remaining bolts, and tighten all bolts to specification. See TORQUE
SPECIFICATIONS table.
3) Install washer and hub nut. Tighten nut securely. Install
NEW cotter pin. Install grease cap. Install caliper. Tighten caliper
bolts and lug nuts to specification. See TORQUE SPECIFICATIONS table.
To complete installation, reverse remove procedure.
REAR BRAKE SHOES
WARNING: Use water or brake cleaner to clean brake parts. DO NOT use
compressed air to remove dirt and dust.
Removal (Dakota & Ram Van)
1) Remove wheel and drum. Note how secondary spring overlaps
primary return spring. Using spring remover, remove brake shoe return
springs. Slide automatic adjuster cable off anchor. Disconnect cable
from adjusting lever.
2) Remove cable, cable guide and anchor plate. See Figs. 3,
4, and 5. Disconnect adjusting lever return spring from lever. Remove
lever and return spring from pivot pin. Remove shoe-to-shoe spring.
Spread shoes, and remove adjustment star wheel.
3) Remove shoe retainers, springs and pins. Remove parking
brake lever from secondary shoe. Remove shoes and parking brake strut
with spring.

being replaced, remove booster check valve and seal.
Installation
1) If new booster is being installed, install check valve and
seal. Position booster on dash, and install lock nuts on booster
mounting studs finger tight. Install booster push rod on brake pedal
pin, and secure rod with NEW retaining clip.
2) Tighten booster lock nuts to specification. Install master
cylinder on booster, and tighten mounting nuts to specification. See
TORQUE SPECIFICATIONS table. Connect vacuum hose to booster check
valve. Start vehicle and check booster operation.
COMBINATION VALVE
Removal & Installation
Raise and support vehicle. Mark brakelines for assembly
reference. Disconnect parking brake cable from clip on valve, if
necessary. Disconnect brake warning light connection at switch.
Disconnect all brake hydraulic lines at valve. Cap brakelines to
prevent dirt from entering system. Remove valve. To install, reverse
removal procedures. Bleed brake system. See BLEEDING PROCEDURES under
BLEEDING BRAKE SYSTEM.
AXLE BEARING & SEAL (FULL FLOATING AXLE)
Removal & Installation (Ram Pickup With 12" & 13" Drums)
1) Raise and support vehicle. Remove wheel. Remove axle shaft
nuts and washers. Strike center of axle flange to free cones. Remove
axle shaft and gasket.
2) Straighten and remove nut lock. Remove adjustment nut and
outer bearing. Remove drum assembly. Remove seal and inner bearing
from drum assembly.
3) Pack inner bearing, and install inner bearing and seal in
drum. Install drum assembly, outer bearing and adjustment nut. While
rotating drum, tighten adjustment nut to specification. See TORQUE
SPECIFICATIONS table.
4) Back off adjustment nut 1/8 turn to obtain .001-.010" (0.
025-0.254 mm) end play. Bend nut lock into spindle keyway. Install
gasket and axle shaft. Install wheel, and lower vehicle. See TORQUE
SPECIFICATIONS table.
OVERHAUL
NOTE: Use illustrations when overhauling components. See
Figs. 2-6.
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS








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Application In. (mm)\
Disc Diameter
Dakota ............................................... 11.30 (287)\
Ram Pickup
1/2 Ton ............................................. 11.57 (294)\
3/4 & 1 Ton ......................................... 12.50 (318)\
Ram Van
1/2 & 3/4 Ton ....................................... 11.75 (299)\
1 Ton ............................................... 12.82 (326)\
Lateral Runout