Front brake assembly for 1996 fatboy

Most likely a warped rotor and with new pads it has locked it's self up.

to replace it: take off the wheel, brake caliper and brake pads. Then you will see the entire hub assembly. Since it's a sealed hub assembly, you can't just repack the bearings. The entire hub assembly needs to be replaced. It was like $90 when I did it on mine. Once you have the assembly off just replace it with the new one and put the calipers and pads back on and it should be good to go at that point.

I your pads are only 2mm (0.080") thick, you are due for some new pads. They should be nearer 20mm thick without measuring the metal backing plate, both of them. Good reason for the rattle.

Good Luck
steve

W hen the rear work fasterr than the front or any wheel grabs faster then you need to check the brake hoses. In your case the front brake hoses could be starting to clog up. they deteriorate from the inside and collapse

Brake Pads
Removal & Installation
Front





3.4L front disc brake assembly









4.0L and 4.7L front disc brake assembly




To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Clip, 2 caliper pins, the anti-rattle spring then remove the 2 brake pads
     and the 4 anti-squeal shims

To Install:

CAUTION
Only replace brake pads on 1 side of the
vehicle at a time. Failure to use this procedure could cause the caliper pistons
on the opposite side of the vehicle to pop out requiring the reconditioning or
replacement of the brake caliper.

1. Remove a small amount of brake fluid from the master cylinder.
   
2. Install a used brake pad into the caliper and compress the caliper pistons.
   
3. Apply disc brake grease to both sides of the inner anti-squeal shims.
   
4. Install or connect the following:
   
   
   
   • Anti-squeal shims to the new brake pads
     NOTE: When replacing worn pads, the anti-squeal shims must be replaced
     together with the pads.
     
     
   • 2 brake pads
     
   • Anti-rattle spring and the 2 caliper pins
     
   • Clip
     
   • Front wheel
   
   
5. Depress the brake pedal several times to seat the brake pads.
   
6. Check the brake fluid level and top off as needed.

Rear
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Rear wheel
     
     
     
     
     
     
     
     
     
     
     
   • 2 cylinder slide pins from rear caliper assembly
     
   • Caliper assembly from rear caliper mounting
     
   • 2 brake pads with anti-squeal shims from rear caliper mounting
     
   • 2 anti-squeal shims from each disc brake pads
     
   • Pad wear indicator plate from the inner side disc brake pad
     
   • 4 pad support plates from the rear caliper mounting

To Install:

1. Install or connect the following:
   
   
   
   • 4 pad support plates on the rear caliper mounting
     
   • Pad wear indicator plate on the inside brake pad
     Note: Install the pad wear indicator facing downward.
     
     
   • Anti-squeal shims on each brake pad
     
   • 2 disc brake pads with anti-squeal shims to the caliper assembly
   
   
2. Apply lithium soap base glycol grease to the sliding part of 2 caliper slide
   pins.
   
3. Install or connect the following:
   
   
   
   • Disc brake caliper assembly with 2 caliper slide pins
     
   • Torque to 65 ft-lbs (88 Nm)
     
   • Rear wheel
   
   
4. Depress the brake pedal several times to seat the brake pads.
   
5. Check the brake fluid level and top off as needed.

--- Removal & Installation
Front
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Front brake caliper assembly
   
   
3. Make matchmarks on the disc and the axle hub.
   
4. Remove the front disc.

To Install:

1. Align matchmarks and disc onto axle hub.
   
2. Install or connect the following:
   
   
   
   • Front brake caliper assembly with the 2 bolts
     
     
     
     1. Torque to 90 ft-lbs (123 Nm)
     
     
   • Front wheel

• To install: Front

1. Compress the piston of the disc brake caliper.
   
2. Install the brake pads and caliper assembly.
   
3. Lubricate the guide pin. Tighten the guide pin to 16-23 ft. lbs. (22-31 Nm).
   

REAR :

1. Pull out the pad springs and then remove the pads and shims.
   

To install:

1. Clean the piston end of the caliper body and the area around the pin holes. Be careful not to get oil on the rotor.
   
2. Carefully turn the piston clockwise back into the caliper body (this can be done with a pair of needle nose pliers). Take care not to damage the piston boot.
   
3. Coat the pad contact area on the mounting support with a silicone based grease.
   

A special tool is available to rotate the caliper piston

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.

Automatic Locking Hub

1. Shift transfer lever to the ``2H'' position, then move vehicle forward and rearward approximately three feet.
2. Raise and support vehicle, then remove wheel and tire assemblies.
3. Disconnect brake hose from caliper.
4. Remove caliper locking bolt.
5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly
6. Remove brake pad support bracket.
7. Remove hub cap retaining bolts, then the hub cap, Fig. 15.
8. Remove housing assembly, snap ring and shims.
9. Remove drive clutch assembly, inner cam and lock washer.
10. Using tool J-36827 or equivalent, remove hub nut.
11. Remove hub and disc assembly.Manual Locking Hub
    
    
    1. Shift transfer lever to the ``2H'' position and set free wheeling hub into Free position.
    2. Raise and support vehicle, then remove wheel and tire assemblies.
    3. Disconnect brake hose from caliper.
    4. Remove caliper locking bolt.
    5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly
    6. Remove brake pad support bracket.
    7. Remove housing assembly retaining bolts then the housing assembly Fig. 16.
    8. Remove snap ring and shims.
    9. Remove body assembly and lock washer.
    10. Using tool J-36827 or equivalent, remove hub nut.
    11. Remove hub and disc assembly

Raise vehicle and remove wheels. Disconnect brakeli
ne from caliper (if necessary). Remove caliper.

On models with free wheeling hub, set control handl
e to FREE position. On all models, remove hub
cover, bolt/washer and hub body. Use tapered punch
to open slits of conical washers. Remove axle shaft

snap ring (if equipped).

Straighten tabs of outer lock washer. Using Spindle
Socket (09607-60020), remove lock nut, lock washer

and adjusting nut. Remove thrust washer and outer b
earing. Remove axle hub and rotor. Remove grease se
al
and inner bearing. Press hub bolts out of axle hub.
Remove retaining bolts, and separate rotor from hu
b.

is it the front or rear locking up? you really have to have this truck loaded (load valve under bed) before the back brakes come on and i think these are the same as my 1999 2500 where the rear is only abs, and not on the front..dumb design i know, but thats how it is...determining if its rear abs only and which axle is locking up will help pin point the problem...i put 100000 miles on my dodge since i got it in 2001 and i put 8 sets of pads on the front and just changed the rear lining and thats only because the rear wheel cylinder was leaking causing the rear brakes to lock up..