Better brakes?

9 LIVES

9 LIVES

Demolition Expert
Truck is pulling hard right when I hit the brakes, so I am going to do a overhaul on the front brakes.

I am contemplating using the truck to haul heavier loads in the bed, I have installed hellwig overload kit to help the bed hold the weight a little better. I am nervous about stopping the load though. Can anything be done on a 94 3500 to get better braking? Since I have owned it I have just put the cheapest pads,rotors & calipers on it that advance auto sells. Would spending more money be worth it for an older truck?
 
I upgraded to Hydraboost system with larger bore master and adjustable proportioning valve from Sweeting Performance and I also have the Borgenson PS pump. HUGE difference. I also have yellow pads and drilled/slotted rotors in the front.

Not cheap. But very noticeable results.
 
IIRC you can get upgraded slave cylinders for the rear. I am thinking the dodge ones are like 7/8" and if you get a GM one they are 1 1/16".
 
I have 1 ton gm cylinders in the rear. Dana 80. Ridiculous how much better they work now.

I’m removing the abs crap next and using a prop valve. The abs system on these trucks will run you right into someone’s azz. Junk. At least it is on my truck.

I’d upgrade to hydroboost over any of that tho
 
bateman said:
I have 1 ton gm cylinders in the rear. Dana 80. Ridiculous how much better they work now.

I’m removing the abs crap next and using a prop valve. The abs system on these trucks will run you right into someone’s azz. Junk. At least it is on my truck.

I’d upgrade to hydroboost over any of that tho
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I think 1 ton dodge might be 1", I think GM had a larger option for the D80
 
I've wondered how hard a 3rd gen axle swap would be on a 2nd gen so you get bigger 4 wheel discs.

Or just 05-up Super Duty axle swap it.
 
I have been through a lot on my old 2nd gen trying to make the brakes work better but honestly they still suck. I have had 2 rear end collisions on the highway where I put my whole weight on that brake pedal and it still isnt enough to get the truck to stop in a reasonable distance. Dont think I have ever locked up the front wheels. Is it even possible on these trucks? How did this setup pass DOT back in 1994? Maybe it was under-designed since it was prior to ABS?
you can put the ford dana 60 outer knuckles and manual hubs on which gives you slightly larger rotors. I cant recall if the calipers are twin piston or not.
If you have a later model truck you can swap to 3rd gen outer knuckles but I forget the cutoff year where you can do that. I cant do it on mine.
Other than that, if you have a second gen all you can do is put on hydro and slotted rotors and better pads.
If you did an axle swap yes you get the option of using larger rotors but then you may have the opposite problem if you go too far with no ABS setup.

at the end of the day, probably better to stuff that cummins into a superduty.
 
Here is something I have noticed and have not been able to find much info on since its more design related than DIY.. when you change the diameter of the wheel the braking system is mounted on it seems like theres more torque against the brakes.
Anyone know of any enthusiast sites that get into the math on this, how to select rotor size, piston area, master cylinder piston diameter, etc?
If I find something first Ill post it here.
 
If you do the hydroboost conversion, you might consider adding a small cooler to the system.
https://www.summitracing.com/parts/hda-677
The above works well in my climate.
I have had trouble with Mopar ATF+4 boiling in factory 2nd gen hydroboost setups when towing during the summer.

Theres also a pretty involved conversion that uses front brake components from a OBS ford.

Dodge Ram 2500 4x4 Dana 60 Hub removal and converison to Ford Knuckles | Pirate 4x4

I believe the best option is to install a complete 00.5 - 02 Dodge D60 front axle and install some 03+ Ram HD brakes. Keep in mind that 01.5 - 02 do not have the CAD system if that matters to you.
 
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I put a cooler on mine when I did the hydro. Never had an issue but I expected it would happen eventually w/o one.
The ford swap looked interesting but you cant usually just buy the knuckles youd have to get the whole axle they usually run close to 900$
I agree the later model dodge axle sounds like a good idea. I just wonder what it does to coil placement, track width and if the axle lines up in the same spot.
 
GaveUpOnTV said:
What makes it not cheap? Looking at the parts and they are only around $250. Is there a lot of labor?
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Doubt you will find anyone that will sell you only the knuckles and hardware for the swap. They all want to sell you a complete axle. Then you have to dispose of the center section you didnt use. Maybe on pirate4x4 youd find someone if youre lucky.
For that money, may as well just get a later model ram axle with the same gear ratio and get a welder / fabricator to install it.
 
I guess I just lucked out, but the brakes on my truck have always been great. Even the ABS system works perfectly. I upgraded to EBC yellow pads in the front and green in the rear just because I could. Still running the original rotors.
 
2002 has a different setup than the older trucks. you can swap to the 3rd gen knuckles on some but I forget what the cutoff year was. I cant do it on my 95 its whats on these older trucks thats really scary. 12" rotor I think? with a single piston caliper.
 
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TheSilverBullet said:
CTD2500 had a write up on brake upgrades for the 94-99 awhile back
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I did some searching cant find a link to it anywhere. But I think I remember reading that on here. or something like it.
Theres also stuff on pirate4x4 about the interchange of axle parts and you need a later model to use the 3rd gen knuckles and brakes on. So people with the earlier trucks like me are boned. May as well save your pennies for a superduty swap the dodge chassis has so many failure points
 
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