2001 DODGE RAM Service Repair Manual

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Page 289 of 2889

DODGE RAM 2001 Service Repair Manual (2) With the engine off depress the brake pedal
several times to discharge the accumulator. Grasp
the accumulator and see if it wobbles or turns. If it
does the accumulator has lost a gas charge and t

Page 290 of 2889

DODGE RAM 2001 Service Repair Manual STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any re

Page 291 of 2889

DODGE RAM 2001 Service Repair Manual INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cy

INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 28 N´m (21 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.
(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: Use only MOPAR power steering fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.(12) Bleed the hydraulic booster.
ROTORS
DIAGNOSIS AND TESTINGÐDISC BRAKE
ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining with a disc
brake lathe if surface scoring and wear are light.
Replace the rotor for the following conditions:
²Severely Scored
²Tapered
²Hard Spots
²Cracked
²Below Minimum Thickness
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if below min-
imum thickness, or if machining would reduce thick-
ness below the allowable minimum.
Rotor minimum thickness is usually specified on
the rotor hub. The specification is either stamped or
cast into the hub surface.
ROTOR RUNOUT
Check rotor lateral runout with dial indicator
C-3339 (Fig. 29). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of the
brake shoes. Position the dial indicator plunger
approximately 25.4 mm (1 in.) inward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maximum allowable rotor runout is 0.127 mm
(0.005 in.).
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 30).
Position the micrometer approximately 25.4 mm (1
in.) from the rotor outer circumference for each mea-
surement.
Thickness should notvaryby more than 0.025 mm
(0.001 in.) from point-to-point on the rotor. Machine
or replace the rotor if necessary.
Fig. 28 Booster Mounting
1 - STEERING COLUMN
2 - MOUNTING NUTS
3 - BOOSTER PEDAL ROD
4 - MOUNTING NUTS
5 - 20 BRAKESBR/BE
POWER BRAKE BOOSTER (Continued)

Page 292 of 2889

DODGE RAM 2001 Service Repair Manual REMOVAL - REAR - 2500/3500
(1) Raise and support the vehicle
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS -

Page 293 of 2889

DODGE RAM 2001 Service Repair Manual (4) Remove the rotor from the hub/bearing wheel
studs.
REMOVAL - 3500 FRONT
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
re

(4) Remove the rotor from the hub/bearing wheel
studs.
REMOVAL - 3500 FRONT
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped.
(4) Remove the brake caliper adapter assembly.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL).
(5) Remove the rotor assembly.
INSTALLATION - REAR - 2500/3500
(1) Install the hub to the rotor. Tighten the bolts to
128 N´m (95 ft. lbs.) (Fig. 33).
(2) Install the hub and rotor assembly.
(3) Install the rear axle shaft to the housing with
dual wheels, (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/REAR AXLE - 286RBI/AXLE SHAFTS -
INSTALLATION).
(4) Install the caliper adapter bolts.
(5) Install the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION). (Fig. 34).
(6) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.
INSTALLATION - 1500/2500 FRONT
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Install rotor onto the hub/bearing wheel studs.
(3) Install the caliper adapter assembly,(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION) and tighten
adapter bolts to:
²LD 1500: 176 N´m (130 ft lbs.)
²HD 2500: 285 N´m (210 ft lbs.)
(4) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE) and lower vehicle.
(5) Apply brakes several times to seat brake shoes.
Be sure to obtain firm pedal before moving vehicle.
INSTALLATION - 3500 FRONT
(1) Position the rotor on the hub/bearing.
(2) Install the brake caliper adapter assembly
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - INSTALLATION) and
tighten adapter bolts to 285 N´m (210 ft. lbs).
(3) Install the wheel and tire assemblies, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(4) Remove the support and lower the vehicle.
(5) Apply brakes several times to seat brake shoes
and caliper piston. Do not move vehicle until firm
brake pedal is obtained.
Fig. 33 ROTOR TO HUB
1 - Hub Bolts
2 - Socket
Fig. 34 ROTOR INSTALLED
5 - 22 BRAKESBR/BE
ROTORS (Continued)

Page 294 of 2889

DODGE RAM 2001 Service Repair Manual BRAKE PADS/SHOES
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the rear wheel and tire assemblies.
(3) Compress the caliper.
(4) Remove caliper mounting bolts
NOTE: Do not allow brake h

Page 295 of 2889

DODGE RAM 2001 Service Repair Manual REMOVAL - FRONT
(1) Raise and support vehicle.
(2) Remove front wheel and tire assemblies.
(3) Compress caliper.
(4) Remove caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- R

Page 296 of 2889

DODGE RAM 2001 Service Repair Manual REMOVAL - REAR BRAKE SHOES-11 inch
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove clip nuts securing brake drum to wheel
studs.
(4) Remove drum. If drum is difficult to

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