2nd Gen Non-Engine/Transmission Brake Problems

[TFunfer]

Hi everyone!



The problem I have been having lately has been intermittent. When I apply the brakes the pedal feels firm. But every now and then as I am braking I hear a clunk and the brakes feel like they release slightly, the brake pedal moves closer to the floor before the brakes start taking effect again. The clunk noise seems to come from the front drivers side of the truck. I don't have any problems stopping but it sure gets my attention.



My truck is a 2001 2500 QC 4x4 with 4-wheel disc brakes. I have about 63k miles on it. I don't see anything obviously wrong with the calipers and the brake pads have at least 60% wear left.



If anyone has experienced this or has an idea what the problem may be I would really like to hear about it. Any ideas would be appreciated.



Thanks in advance.

 

[AKAMAC]

Does the truck pull at all before you get the "clunk"? I would really be concerned with any problem in braking system. Mike

 

[vssman]

Do you think the ABS is activating? If so, try pulling the fuse and go for a ride to see if it goes away.

 

[RT66DOC]

Welcome to TDR Land.

 

[TFunfer]

RT66DOC- Thanks for the welcome.



AKAMAC- The truck does not pull to either side. It continues to brake straight ahead.



VSSMAN- It doesn't feel like the ABS activating. I have had the ABS come on in the winter and this feels totally different.



One thing I forgot to mention is that a few times when it happened, it coincided with pressing the clutch. For example, while I was braking to a stop everything was normal until I pushed in the clutch to downshift and the whole episode with the brake pedal occured. But again not all the time and not always in conjunction with pushing the clutch pedal.



It is an intermittent problem that I am running out of ideas as to what can be causing it. It is about 180 miles to the nearest Dodge dealer so any ideas any of you might have would be appreciated.

 

[Diesel Gunner]

I have not had this problem, but, as soon as you mentioned that it happens when you put the clutch in I got very suspicious of the clutch and brake pedal assembly and mounting. I would suggest that you take an inspection mirror and flashlight with you and become intimately familiar with that area inside and outside of the cab. Look for cracking, missing nuts and/or bolts, or anything that just does not look right. By the way, did I say become intimately familiar?



A little sore back from laying on the floorboards is prefferable to broke back from accident. (Old Chinese Proverb)

 

[AKAMAC]

What the Gunner said, look for loose mounting hardware! Your pedal mounts may be loose.

 

[TFunfer]

Diesel Gunner



Thanks for the reply. I have been under the dash with a flashlight and have had a good look at the assembly. I can't find anything that looks out of place. The clunk and pedal feel I described earlier does not always occur in conjunction with depressing the clutch. This may have been just a coincidence. But I haven't ruled any connection with the two out. A few times I have had my windows open when this happened and I definately heard something outside of the cab. Seems to be on the drivers side up front.



Today I found that if I back up and apply the brakes firmly and then drive forward and apply the brakes I hear a clack sound out of the front brake caliper. It does it every time. I am not sure if this is normal but I will be pulling that caliper off and having a closer look at it and the brake pads.



One thought is perhaps a valve or something is sticking in the master cylinder and when it releases the clunk I hear is maybe some play in the driveline.



The search continues...

 

[Diesel Gunner]

No, clunking from the front brake is not normal. You are correct in pulling that wheel and doing a thorough inspection (flashlight and inspection mirror). I am crazy about being able to stop. I am also not crazy about being sued out of existance because of something that I should have done something about.



I will keep an eye on this thread and let you know if I come up with any other ideas.



Have you tried having someone else (that you trust) drive the truck while you are as close as you can get to the floorboard area? But, still check that left front brake first.

 

[B.G. Smith]

Originally posted by vssman

Do you think the ABS is activating? If so, try pulling the fuse and go for a ride to see if it goes away.

I'M with vssman, the ABS activating on dry road surface would feel a lot more severe than it would in winter type driving. I think pulling the fuse is a good way to check it out. bg

 

[TFunfer]

Hey everyone, sorry it has taken me so long to get back to this thread but I have been very busy at work.



Here is what I have found so far:



I thoroughly inspected the clutch/brake pedal assembly as best I could without actually disassembling it and found nothing wrong with it.



I inspected the booster and master cylinder assembly and re-torqued the mounting nuts on the firewall and again everything looks good.



I then started with the front driver's side brake caliper and everything looked fine. The pads had about 60% wear left on them but the inside pad showed signs of it beginning to separate at one corner between the pad material and the metal plate. At this point I decided not to fool around and replaced the front brake pads. The front right side pads also had about 60% wear left on them and the inside pad was also showing signs of beginning to separate.



When I was finished with the front brakes I then started on the rear brakes. I drive with my truck empty about 95% of the time and expected the rear brakes to be in better shape than the fronts but that was not the case.



I started with the right rear caliper and everything looked good until I removed the brake pads. The pads had about 70% wear left but the inside pad showed definite signs of separation, in fact when I pulled lightly on the pad material it completely separated from the metal plate in one piece. :--) . I then immediately pulled the driver's rear caliper off and again there was about 70% wear left on the pads but the inside pad completely separated from the metal plate before I could remove it. :--) SCARY!!!



I have never seen brake pads do this. My last truck was a chevy and in 165,000 miles I only had to replace the pads once. There was still a lot of wear left on these pads but they were falling apart. Has anyone else had this problem with their Dodge trucks? I don't know who is Dodge's supplier of brake pads but I replaced them with Asbestos pads.



So far the problem has not reoccurred since so I am keeping my fingers crossed.



Thanks to all for your replies and I will let you know if anything comes up.

 

[TFunfer]

Asbestos!!? Oops!



That last post should have said I replaced my brake pads with Raybestos pads.

 

[dewey88]

TFunfer,

That is so weird that this same thing happened to me over the weekend! I was heading out for the long weekend and got halfway to our destination and had one of the calipers (I thought lock-up) on me! So I stopped and took a look at it and could not find anything wrong at the time! So we got to our cottage and I took the rear tire off to check things out a little more and there it was, the rear brake pads were seperated from the metal holder parts, both sides!!! I have got about 67,000 miles on mine 2001 QC and I see you have about 62 or 63,000 miles! But in the mean time getting up there to the cottage it was doing the same thing you described earlier and it felt like my foot was going to go through the floor sometimes! So I put new pads on the rears and I have not had a problem since, it has only been 2 days but nothing like I was experimenting! I was told by a dealer that the rear brakes are controlled by the computer, and that if you haul heavy loads alot that it componsates for that and puts more braking to the rears than the fronts, now I don't know if this is true or not, so don't quote me! Let me know how you come out on this deal, talk to ya later!

 

[TFunfer]

Dewey88,

So far the brakes are working good. It has been about 10 days and just over 100 miles with the new pads and the problem hasn't reoccurred. Although before, the problem was very intermittent and hadn't occurred for about 3 days prior to me looking at the brake pads. I just hope this has solved it, if not I will start looking into the ABS system.



From now on I will be taking my calipers off when I check for wear on the brake pads not just look at them on the truck. This has been a real eye opener.



Glad to hear your problem has gone away with the new pads as well.



Cheers!