2001 DODGE RAM Service Repair Manual

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Page 297 of 2889

DODGE RAM 2001 Service Repair Manual (7) Remove adjuster cable. Slide cable eye off
anchor pin. Then unhook and remove cable from
adjuster lever.
(8) Remove cable guide from secondary shoe and
anchor plate from anchor pin.
(9) Remove adj

(7) Remove adjuster cable. Slide cable eye off
anchor pin. Then unhook and remove cable from
adjuster lever.
(8) Remove cable guide from secondary shoe and
anchor plate from anchor pin.
(9) Remove adjuster lever. Disengage lever from
spring by sliding lever forward to clear pivot and
work lever out from under spring.
(10) Remove adjuster lever spring from pivot.
(11) Disengage and remove shoe to shoe spring
from brake shoes.
(12) Disengage and remove adjuster screw assem-
bly from brake shoes.
(13) Remove brake shoe retainers, springs (Fig.
46).
(14) Remove secondary brake shoe from support
plate.
(15) Remove strut and spring (Fig. 46).
(16) Remove parking brake lever retaining clip
from the secondary shoe and remove the lever.
(17) Remove primary shoe from support plate.
(18) Disengage parking brake lever from parking
brake cable.
(19) Remove parking brake cable guide spring.
REMOVAL - 12 1/8 INCH
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.(3) Remove clip nuts securing brake drum to wheel
studs.
(4) Remove brake drum.
(5) Vacuum brake components to remove brake lin-
ing dust.
(6) Unhook adjusting lever return spring from
lever.
(7) Remove lever and return spring from lever
pivot pin.
(8) Unhook adjuster lever from adjuster cable
assembly.
(9) Remove shoe-to-shoe upper spring (Fig. 47).
(10) Remove shoe hold-down springs (Fig. 48).
(11) Disconnect parking brake cable from parking
brake lever.
(12) Remove shoe-to-shoe lower spring and
adjuster assembly .
(13) Remove brake shoes (Fig. 49).
INSTALLATION - REAR
(1) Clean caliper mounting adapter and anti-rattle
springs.
(2) Lubricate anti-rattle springs with Mopar brake
grease.
(3) Install anti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
(4) Install inboard brake shoe in adapter.
(5) Install outboard brake shoe in adapter.
(6) Tilt the bottom of the caliper over rotor and
under adapter. Then push the top of the caliper down
onto the adapter.
Fig. 46 Shoe Retainers, Springs and Pins
1 - SECONDARY SHOE AND LINING
2 - STRUT AND SPRING
3 - SPRING
4 - PIN
5 - RETAINER
6 - PRIMARY SHOE AND LINING
7 - TOOL C-4070
Fig. 47 Upper Spring
5 - 26 BRAKESBR/BE
BRAKE PADS/SHOES (Continued)

Page 298 of 2889

DODGE RAM 2001 Service Repair Manual (7) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION) (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/DISC BRAKE CALIPERS -
INSTALLATION).
(8) Install wheel

Page 299 of 2889

DODGE RAM 2001 Service Repair Manual (3) Lubricate adjuster screw socket, nut, button
and screw thread surfaces with grease or Lubriplate.
(4) Install parking brake lever to the secondary
shoe and install retaining clip.
(5) Install prim

(3) Lubricate adjuster screw socket, nut, button
and screw thread surfaces with grease or Lubriplate.
(4) Install parking brake lever to the secondary
shoe and install retaining clip.
(5) Install primary shoe on support plate. Secure
shoe with new spring retainers and pin.
(6) Install spring on parking brake strut and
engage strut in primary.
(7) Install secondary shoe on support plate (Fig.
51). Insert strut in shoe and guide shoe onto anchor
pin. Temporarily secure shoe with retaining pin.
(8) Install anchor plate and adjuster cable eyelet
on support plate anchor pin.
(9) Install cable guide in secondary shoe and posi-
tion cable in guide.
(10) Assemble adjuster screw (Fig. 52). Then
install and adjuster screw between the brake shoes.
CAUTION: Be sure the adjuster screws are installed
on the correct brake unit. The adjuster screws are
marked L (left) and R (right) for identification.
(11) Install adjuster lever and spring and connect
adjuster cable to lever.
(12) Install secondary shoe retainers and spring.
(13) Install shoe to shoe spring to secondary shoe,
then to primary shoe.(14)
Verify adjuster operation. Pull adjuster cable
upward, cable should lift lever and rotate star wheel. Be
sure adjuster lever properly engages star wheel teeth.
(15) Install the parking brake cable into guide
spring and insert cable into the backing plate.
(16) Adjust brake shoes to drum with brake gauge.
(17) Install wheel and tire assembly, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(18) Remove support and lower the vehicle.
INSTALLATION - 12 1/8 INCH
NOTE: Pivot screw and adjusting nut have left hand
threads on left side brake and right hand threads
on right side brake. Verify that adjusting nuts are
installed on correct side of vehicle.
(1) Coat contact pads on support plate with Mopar
high temperature grease, multi-mileage grease, or
equivalent.
(2) Assemble adjuster, lower spring and both brake
shoes. Then position the assembled components on
the support plate.
NOTE: Primary shoe is installed toward the front of
the vehicle and secondary toward the rear of the
vehicle.
(3) Install brake shoe hold-down springs and pins.
Be sure hold-down pins are seated in support plate
and springs are connected (Fig. 53).
(4) Insert parking brake cable through parking
brake cable guide spring to parking brake lever. Be
sure cable end is properly secured in lever.
(5) Install upper spring.
Fig. 51 Brake Shoe Installation
1 - SHOE RETURN SPRING
2 - ANCHOR PLATE
3 - ADJUSTER CABLE
4 - SHOE RETAINING PIN
5 - SECONDARY SHOE AND LINING
6 - PRIMARY SHOE AND LINING
7 - STRUT AND SPRING
Fig. 52 Adjuster Screw
1 - WASHER
2 - SOCKET
3 - STAMPED LETTER
L-LEFT BRAKE
R-RIGHT BRAKE
4 - SCREW THREADS
5 - NUT
6 - BUTTON
5 - 28 BRAKESBR/BE
BRAKE PADS/SHOES (Continued)

Page 300 of 2889

DODGE RAM 2001 Service Repair Manual (6) Position adjuster lever return spring on pivot.
(7) Install adjuster lever.
(8) Attach adjuster cable to adjuster lever. Be sure
cable is properly routed.
(9) Adjust brake shoes to drum with brake

(6) Position adjuster lever return spring on pivot.
(7) Install adjuster lever.
(8) Attach adjuster cable to adjuster lever. Be sure
cable is properly routed.
(9) Adjust brake shoes to drum with brake gauge.
MASTER CYLINDER
DESCRIPTION
A two-piece master cylinder is used on all models.
The cylinder body containing the primary and sec-
ondary pistons is made of aluminum. The removable
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the
hydraulic brake circuits. The reservoir is the only
serviceable component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
cuit separation in the event of a front or rear brake
malfunction. The reservoir compartments will retain
enough fluid to operate the functioning hydraulic cir-
cuit.
Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
the cylinder fluid ports can be damaged if care is not
exercised. Start all brake line fittings by hand to
avoid cross threading.
The cylinder reservoir can be replaced when neces-
sary. However, the aluminum body section of the
master cylinder is not a repairable component.
NOTE: If diagnosis indicates that an internal mal-
function has occurred, the aluminum body section
must be replaced as an assembly.
OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action. It should
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately turn off igni-
tion to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 54).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 55).
Fig. 53 Hold-Down Spring And Pin Attachment
1 - SHOE HOLD DOWN SPRING
2 - HOLD DOWN PIN
3 - BACKING PLATE
4 - BRAKE SHOE WEB
BR/BEBRAKES 5 - 29
BRAKE PADS/SHOES (Continued)

Page 301 of 2889

DODGE RAM 2001 Service Repair Manual (5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDUREÐMASTER CYLINDER
BLEEDING
A new master cylinder should be bled b

Page 302 of 2889

DODGE RAM 2001 Service Repair Manual (4) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE)
WHEEL CYLINDERS
REMOVAL
(1) Raise vehicle and remove tire and wheel
assembly.
(2) Remove brake drum.
(3)

(4) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE)
WHEEL CYLINDERS
REMOVAL
(1) Raise vehicle and remove tire and wheel
assembly.
(2) Remove brake drum.
(3) Lift adjuster lever away from adjuster screw.
Then turn screw star wheel until screw is fully
retracted.
(4) Remove brake shoe return springs, adjuster
spring and adjuster screw. Move upper ends of brake
shoes apart to provide removal clearance for wheel
cylinder links.
(5) Disconnect brake line from wheel cylinder.
(6) Remove wheel cylinder attaching screws and
remove cylinder from support plate
DISASSEMBLY
(1) Remove push rods and boots (Fig. 58).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
CLEANING
Clean the cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air.
Do not use rags or shop towels to dry the cylindercomponents. Lint from cloth material will adhere to
the cylinder bores and pistons.
INSPECTION
Inspect the cylinder bore. Light discoloration and
dark stains in the bore are normal and will not
impair cylinder operation.
The cylinder bore can be lightly polished but only
with crocus cloth. Replace the cylinder if the bore is
scored, pitted or heavily corroded. Honing the bore to
restore the surface is not recommended.
Inspect the cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
corrosion. Replace the pistons if worn, scored, or cor-
roded. Do attempt to restore the surface by sanding
or polishing.
Discard the old piston cups and the spring and
expander. These parts are not reusable. The original
dust boots may be reused but only if they are in good
condition.
ASSEMBLY
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander with clean brake fluid.
(2) Install first piston in cylinder bore. Then
install first cup in bore and against piston.Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) Install spring and expander followed by
remaining piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
Fig. 57 Master Cylinder
1 - MOUNTING NUT
2 - MOUNTING NUT
3 - BRAKE LINES
4 - MASTER CYLINDER
Fig. 58 Wheel Cylinder Components±Typical
1 - SPRING
2 - CYLINDER
3 - PISTON CLIP
4 - BOOT
5 - PUSH ROD
6 - PISTON
7 - BLEED SCREW
8 - CUP EXPANDERS
BR/BEBRAKES 5 - 31
MASTER CYLINDER (Continued)

Page 303 of 2889

DODGE RAM 2001 Service Repair Manual INSTALLATION
(1) Apply thin coat of silicone sealer to wheel cyl-
inder mounting surface of support plate (Fig. 59).
Sealer prevents road splash from entering brake
drum past cylinder.
(2) Start brake

INSTALLATION
(1) Apply thin coat of silicone sealer to wheel cyl-
inder mounting surface of support plate (Fig. 59).
Sealer prevents road splash from entering brake
drum past cylinder.
(2) Start brake line in cylinder inlet by hand. Do
not tighten fitting at this time.
(3) Mount wheel cylinder on support plate and
install cylinder attaching screws. Tighten screws to
20 N´m (15 ft. lbs.).
(4) Tighten brake line fitting to 13 N´m (115 in.
lbs.).
(5) Install brake shoe components.
(6) Adjust brake shoes to drum using brake gauge.
(7) Install brake drum.
(8) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(9) Install wheel and tire assemblies, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE) and lower vehicle.
SUPPORT PLATE
REMOVAL
(1) Remove wheel and tire assemblies.
(2) Remove brake drums
(3) Remove axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(4) Remove brake shoes and hardware for access to
parking brake cable.
(5) Remove parking brake cable from support
plate.(6) Disconnect brake line at wheel cylinder and
remove cylinder.
(7) Remove bolts attaching support plate to axle
and remove support plate.
INSTALLATION
(1) Apply thin bead of silicone sealer around axle
mounting surface of support plate.
(2) Install support plate on axle flange. Tighten
attaching bolts to 47-68 N´m (35-50 ft. lbs.).
(3) Apply thin bead of silicone sealer around wheel
cylinder mounting surface. Install wheel cylinder on
new support plate.
(4) Install parking brake cable in support plate.
(5) Install brake shoes and hardware.
(6) Install axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - INSTALLATION).
(7) Adjust brake shoes to drum with brake gauge.
(8) Install brake drums.
(9) Fill and bleed brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(10) Install wheel and tire assemblies, (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE) and lower vehicle.
DRUM
DESCRIPTION
All 1500 models and early year production
2500/3500 are equipped with rear drum brake assem-
blies. They are two-shoe, duo-servo units with an
automatic adjuster mechanism.
Drum brake assemblies used:
²1500 models: 11 x 2.25 in.
²2500/3500 models: 12 1/8 x3.5 in.
The drum brakes are a semi-floating, self-energiz-
ing, servo action design. The brake shoes are not
fixed on the support plate. This type of brake allows
the shoes to pivot and move vertically to a certain
extent.
OPERATION
In operation, fluid apply pressure causes the wheel
cylinder pistons to move outward. This movement is
transferred directly to the brake shoes by the cylin-
der connecting links. The resulting brake shoe expan-
sion brings the lining material into contact with the
rotating brake drum.
Two forces affect the brake shoes once they contact
the drum. The first force being hydraulic pressure
exerted through the wheel cylinder pistons. And the
second force is the friction generated turning torque
of the rotating drum.
Fig. 59 Wheel Cylinder Mounting Surface
1 - CYLINDER MOUNTING SURFACE
2 - SUPPORT PLATE
3 - APPLY THIN SEALER COAT HERE
5 - 32 BRAKESBR/BE
WHEEL CYLINDERS (Continued)

Page 304 of 2889

DODGE RAM 2001 Service Repair Manual The drum forces both brake shoes to move in the
same direction of rotation. Servo action begins with
the primary brake shoe which begins to wedge (or
wrap) itself against the rotating drum surface. Th

The drum forces both brake shoes to move in the
same direction of rotation. Servo action begins with
the primary brake shoe which begins to wedge (or
wrap) itself against the rotating drum surface. This
force is transmitted equally to the secondary brake
shoe through the adjuster screw and anchor pin. The
net result is that each shoe helps the other exert
extra force against the drum. It is servo action that
creates the wedging (or wrap) effect which produces
increased force on the drum braking surface.
All drum brake assemblies are equipped with a self
adjusting mechanism. The components forming the
mechanism consist of the: adjuster screw, adjuster
lever, actuating lever (11 inch brake), lever return
spring and the adjuster lever spring. The adjuster
lever on the 12 inch brake, is also equipped with a
lever and tension spring.
The adjuster mechanism performs two important
functions. First, is in maintaining proper brake shoe
operating clearance. And second, is to maintain brake
pedal height. The mechanism does so, by adjusting
the shoes in small increments to compensate for lin-
ing wear. The adjustment process is continuous
throughout the useful life of the brake lining.
The adjuster components are all connected to the
secondary brake shoes. Actual adjustment only
occurs during reverse brake stops. Secondary brake
shoe movement (during reverse stops), is what acti-
vates the adjuster components.
In operation, secondary shoe movement causes the
adjuster lever spring to exert pull on the lever. This
pivots the lever away from the adjuster screw teeth.
When the stop is completed and the brakes released,
the adjuster lever pivots back to a normal position. It
is during this return movement of the lever when
adjustment occurs. At this point, the lever comes
back into contact with the adjuster screw teeth as it
moves upward. The lever will then rotate the
adjuster screw one or two teeth as needed for adjust-
ment.
NOTE: The adjustment process requires a complete
stop to actually occur. Rolling stops will NOT acti-
vate the adjuster components. In addition, the
adjuster screws are left and right hand parts and
must NOT be interchanged.
DIAGNOSIS AND TESTING - BRAKE DRUM
The maximum allowable diameter of the drum
braking surface is indicated on the drum outer edge.
Generally, a drum can be machined to a maximum of
1.52 mm (0.060 in.) oversize. Always replace the
drum if machining would cause drum diameter to
exceed the size limit indicated on the drum.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rate gauge. The most accurate method of measure-
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial indi-
cator.
Variations in drum diameter should not exceed
0.069 mm (0.0028 in.). Drum runout should not
exceed 0.18 mm (0.007 in.) out of round. Machine the
drum if runout or variation exceed these values.
Replace the drum if machining causes the drum to
exceed the maximum allowable diameter.
STANDARD PROCEDURE - BRAKE DRUM
MACHINING
The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim-
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
CLEANING
Clean the individual brake components, including
the support plate and wheel cylinder exterior, with a
water dampened cloth or with brake cleaner. Do not
use any other cleaning agents. Remove light rust and
scale from the brake shoe contact pads on the sup-
port plate with fine sandpaper.
INSPECTION
As a general rule, riveted brake shoes should be
replaced when worn to within 0.78 mm (1/32 in.) of
the rivet heads. Bonded lining should be replaced
when worn to a thickness of 1.6 mm (1/16 in.).
Examine the lining contact pattern to determine if
the shoes are bent or the drum is tapered. The lining
should exhibit contact across its entire width. Shoes
exhibiting contact only on one side should be
replaced and the drum checked for runout or taper.
Inspect the adjuster screw assembly. Replace the
assembly if the star wheel or threads are damaged,
or the components are severely rusted or corroded.
BR/BEBRAKES 5 - 33
DRUM (Continued)

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