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TSB 05-02-95

Front Disc Brake Noise

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Date: Mar. 24, 1995

Models: 1994-1995 (BR) Ram Truck

NOTE: THIS BULLETIN APPLIES TOP ALL 3500 4X4/4X2 AND 2500 4X4 HD (8800 GVW) VEHICLES EQUIPPED WITH 86M DIAMETER CALIPER PISTONS.

Symptoms:

A squeal type noise may be heard from the front disc brakes while applying the brakes for a normal stop.  

Diagnosis:

Road test the vehicle, making frequent stops, to ensure the brakes are at operating temperature. If noise is heard, perform the repair procedure.  

Repair:

This bulletin involves grinding or filing a chamfer (bevel) on both ends of the front brake pads.

1.    Raise vehicle on appropriate hoist.

2.    Remove front wheel and tire assemblies.

3.    Press caliper piston back into bore with large flat blade screwdriver. Use large C-clamp to bottom piston in bore if additional force is required. Some brake fluid my need to be removed from the master cylinder to complete this step.

4.    Remove caliper mounting bolts with 3/8" hex wrench or socket.  

5.    Rotate caliper rearward off rotor and out of steering knuckle support ledges.

6.    Remove inboard and outboard brake pads.

7.    Measure pads to ensure that there is more than 13mm of linings/shoe assembly remaining. See figures 1 & 2 for measurement positions. If less than 13mm, new linings should be obtained before proceeding to step 8.

 

8.    Grind or file a chamfer (bevel) on inner and outer pads at both ends of the lining (see Figures 3 & 4). Perform the sane procedure for both the right and left pad Lining assemblies.

 

9.    Clean caliper and steering knuckle slide surfaces with a wire brush. Then apply coat of Mopar Caliper Slide Grease, P/N J8993704, to slide surfaces.

10.  Lubricate caliper mounting bolts, collars, bushings and bores. Coat mounting pin and interior of bushings with silicone grease.

11.   Install inboard brake pad in caliper. Be sure spring clip on pad is properly aligned and seated in caliper piston.

12.   Install outboard brake pad in caliper. Be sure spring ends are seated in dimples in caliper.

13.   Install caliper over rotor and into steering knuckle mounting arms. Be sure caliper is seated flush on mounting arm surfaces.

14.   Start caliper mounting bolts by hand to avoid cross threading. Then tighten mounting bolts to 51 Nm (38 ft. lbs).

15.   Install wheel and tire assemblies.

16.   Lower vehicle and tighten wheel lug nuts to 163-203 NM (120-150 ft. lb.).

17.   Pump brake pedal to reseat caliper pistons and brake pads.

CAUTION: DO NOT NOW VEHICLE UNTIL PADS HAVE BEEN PROPERLY SEATED

18.   Check brake fluid level and add fluid if necessary.

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 05-70-22-94 . . . . . . . . . . . . . . . . . 0.7 Hrs.

FAILURE CODE: XX - Service Adjustment


Thanks to Barry Drodge for supplying the TSB information

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This page was edited on: May 3, 2004