2001 DODGE RAM lock

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 remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 26).
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal. (Fig. 27).
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster (Fig. 28).
Fig. 26 Master Cylinder And Booster
1 - MASTER CYLINDER
2 - RETURN LINE
3 - LINE FROM PUMP
4 - HYDRAULIC BOOSTER
5 - LINE TO GEAR
Fig. 27 Booster Push Rod
1 - BOOSTER PUSH ROD
2 - WASHER
3 - CLIP
4 - PEDAL
BR/BEBRAKES 5 - 19
POWER BRAKE BOOSTER (Continued)

(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)

Discard the brake springs and retainer components
if worn, distorted or collapsed. Also replace the
springs if a brake drag condition had occurred. Over-
heating will distort and weaken the springs.
Inspect the brake shoe contact pads on the support
plate, replace the support plate if any of the pads are
worn or rusted through. Also replace the plate if it is
bent or distorted (Fig. 60).
ADJUSTMENT - REAR BRAKE DRUM
The rear drum brakes are equipped with a self-ad-
justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
Adjustment can be made with a standard brake
gauge or with adjusting tool . Adjustment is per-
formed with the complete brake assembly installed
on the backing plate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parking brakes are fully released.
(2) Raise rear of vehicle and remove wheels and
brake drums.
(3) Verify that left and right automatic adjuster
levers and cables are properly connected.
(4) Insert brake gauge in drum. Expand gauge
until gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 61).
(5) Reverse gauge and install it on brake shoes.
Position gauge legs at shoe centers as shown (Fig.
62). If gauge does not fit (too loose/too tight), adjust
shoes.
(6) Pull shoe adjuster lever away from adjuster
screw star wheel.(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Continue adjustment
until gauge outside legs are light drag-fit on shoes.
(8) Install brake drums and wheels and lower
vehicle.
(9) Drive vehicle and make one forward stop fol-
lowed by one reverse stop. Repeat procedure 8-10
times to operate automatic adjusters and equalize
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
Fig. 60 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
Fig. 61 Adjusting Gauge On Drum
1 - BRAKE GAUGE
2 - BRAKE DRUM
Fig. 62 Adjusting Gauge On Brake Shoes
1 - BRAKE GAUGE
2 - BRAKE SHOES
5 - 34 BRAKESBR/BE
DRUM (Continued)

OPERATION - 2500/3500 WITH REAR DISC
BRAKES
To apply the parking brake the pedal is depressed.
This creates tension in the cable which pulls forward
on the park brake lever. The lever pushes the park
brake shoes outward and into contact with the drum
section of the rotor. The contact of shoe to rotor parks
the vehicle.
A torsion locking mechanism is used to hold the
pedal in an applied position. Parking brake release is
accomplished by the hand release.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
ing light whenever the parking brake is applied.
Parking brake adjustment is controlled by a cable
tensioner mechanism. The cable tensioner, once
adjusted at the factory, should not need further
adjustment under normal circumstances. Adjustment
may be required if a new tensioner, or cables are
installed, or disconnected.
OPERATION - (1500 models) (Early 2500/3500
models with rear drum brakes)
To apply the parking brakes, the pedal is
depressed. This pulls the rear brake shoe actuating
levers forward. As the actuating lever is pulled for-
ward, the parking brake strut or cam, exerts a linear
force against the primary brake shoe. This action
presses the primary shoe into contact with the drum.
Once the primary shoe contacts the drum, force is
exerted through the strut/cam. This force is trans-
ferred through the strut/cam to the secondary brake
shoe causing it to pivot into the drum as well.
A torsion locking mechanism is used to hold the
pedal in an applied position. Parking brake release is
accomplished by the hand release.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
ing light whenever the parking brake is applied.
Parking brake adjustment is controlled by a cable
tensioner mechanism. The cable tensioner, once
adjusted at the factory, should not need further
adjustment under normal circumstances. Adjustment
may be required if a new tensioner, or cables are
installed, or disconnected.
PEDAL
REMOVAL
(1) Release the parking brake.
(2) Raise the vehicle.(3) Loosen the cable tensioner nut at the equalizer
to create slack in the front cable.
(4) Lower the vehicle.
(5) Remove the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(6) Disconnect the brake lamp wire from the
switch on the pedal assembly.
(7) Roll the carpet back, loosen the front cable
grommet from the floorpan and the cable retainer.
(8) Disengage the cable end connector (Fig. 65)
from the arm on the pedal assembly.
(9) Remove the bolts/nuts from the pedal assembly
and remove the assembly.
INSTALLATION
(1) Position the replacement pedal assembly on the
dash and cowl.
(2) Install the bolts/nuts and tighten to 28 N´m (21
ft. lbs.).
(3) Connect the front cable to the arm on the pedal
assembly.
(4) Tighten the front cable grommet to the floor-
pan and the cable retainer, roll the carpet back.
(5) Connect the wires to the brake lamp switch.
(6) Install the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(7) Raise the vehicle.
(8) Adjust the parking brake cable tensioner.
Fig. 65 Parking Brake Pedal Assembly
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
5 - 36 BRAKESBR/BE
PARKING BRAKE (Continued)

CABLES
REMOVAL - REAR PARK BRAKE CABLE -
2500/3500 WITH REAR DISC BRAKES
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 66).
(3) Loosen cable adjuster nut.
(4) Remove the rear park brake cable from the
intermediate park brake cable.
(5) Compress tabs on cable end fitting on the rear
park brake cable to the frame mount bracket. Then
pull the cable through the bracket.
(6) Disengage the park brake cable from behind
the rotor assembly. (Fig. 67).(7) Compress cable tabs on each cable end fitting
at the brake cable support plate.
(8) Remove the cables from the brake cable sup-
port plates.REMOVAL - FRONT PARKING BRAKE CABLE
(1) Raise and support vehicle.
(2) Loosen adjusting nut to create slack in front
cable.
(3) Remove the front cable from the cable connec-
tor.
(4) Compress cable end fitting at underbody
bracket and remove the cable from the bracket.
(5) Lower vehicle.
(6) Push ball end of cable out of pedal clevis with
small screwdriver.
(7) Compress cable end fitting at the pedal bracket
and remove the cable (Fig. 68).
(8) Remove the left cowl trim and sill plate.
(9) Pull up the carpet and remove the cable from
the body clip.
(10) Pull up on the cable and remove the cable
with the body grommet.
REMOVAL - REAR PARK BRAKE CABLES -
1500 SERIES
(1) Release parking brakes.
(2) Raise and support vehicle.
(3) Loosen cable adjuster nut.
Fig. 66 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 67 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
Fig. 68 Parking Brake Pedal
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
BR/BEBRAKES 5 - 37

(4) Remove the rear cables from the cable connec-
tors.
(5) Compress tabs on cable end fitting on the right
rear cable (Fig. 69) at the equalizer. Then pull the
cable through the bracket.
(6) Compress tabs on cable end fitting on the left
rear cable at the frame bracket and pull both cables
through the frame bracket.
(7) Pull the right rear cable through the brake
hose bracket and remove the cable retainers from the
axle.
(8) Remove rear wheels and brake drums (1500
series only).
(9) Disconnect each cable from the park brake
lever.
(10) Remove the parking brake cable guide spring.
(11) Compress cable tabs on each cable end fitting
at the brake support plate.
(12) Remove the cables from the brake support
plates.
REMOVAL - REAR PARK BRAKE CABLES
2500/3500 SERIES WITH DRUM BRAKES
(1) Release parking brakes.
(2) Raise and support vehicle.
(3) Loosen cable adjuster nut.
(4) Remove the rear cables from the cable ten-
sioner bracket (Fig. 70).
(5) Remove the right rear cable O-ring. Then pull
the cable through the bracket.
(6) Compress tabs on them left cable end fitting.
Then pull the cable through the frame bracket.(7) Pull the right rear cable through the brake
hose bracket and remove the cable retainers from the
axle.
(8) Remove rear wheels and brake drums.
(9) Disconnect each cable from the park brake
lever.
(10) Remove cable guide spring.
(11) Compress cable tabs on each cable end fitting
at the brake support plate.
(12) Remove the cables from the brake support
plates.
INSTALLATION - REAR PARK BRAKE CABLE -
2500/3500 WITH REAR DISC BRAKES
(1) Push each cable end through the brake cable
support plate hole until the cable end fitting tabs
lock into place.
NOTE: Pull on the cable to ensure it is locked into
place.
(2) Push the cable through the frame bracket.
(3) Lock the left cable end fitting tabs into the
frame bracket hole.
(4) Install the rear cables into the tensioner rod
behind the rear of the brake assembly.
(5) Install the cable to the intermediate cable con-
nector.
(6) Release and remove the lock out device.
(7) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(8) Remove the supports and lower the vehicle.
Fig. 69 Cables And Tensioner
1 - EQUALIZER
2 - RIGHT CABLE
3 - LEFT CABLE
4 - CABLE BRACKET
5 - TENSIONER
6 - TENSIONER NUT
Fig. 70 Cables And
1 - ADJUSTER NUT
2 - TENSIONER
3 - CABLE CONNECTOR
4 - 6.35MM
(1/4 IN.)
5 - REAR CABLES
5 - 38 BRAKESBR/BE
CABLES (Continued)

INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) From inside the vehicle, insert the cable end
fitting into the hole in the pedal assembly.
(2) Seat the cable retainer in the pedal assembly.
(3) Engage the cable ball end in clevis on the pedal
assembly.
(4) Route the cable along the top of the wheel well
and clip in place.
(5) Route the cable through the floorpan and
install the body grommet.
(6) Place the carpet down and install the left cowl
trim and sill plate.
(7) Raise and support the vehicle.
(8) Route the cable through the underbody bracket
and seat the cable housing retainer in the bracket.
(9) Connect the cable to the cable connector.
(10) Perform the park brake adjustment proce-
dure, (Refer to 5 - BRAKES/PARKING BRAKE/CA-
BLE TENSIONER - ADJUSTMENTS).
(11) Lower the vehicle.
INSTALLATION - REAR PARK BRAKE CABLES -
1500 SERIES
(1) Install the parking brake cable guide spring.
(2) Install the brake drums.
(3) Pull back on the cable. Then push the cable
through the brake support plate hole to engage the
cable in the park brake lever.
NOTE: Pull on the cable end to ensure it is attached
to the park brake lever.
(4) Push each cable end through the brake support
plate hole until the cable end fitting tabs lock into
place.
NOTE: Pull on the cable to ensure it is locked into
place.
(5) Install the right cable retainers on the axle.
Route the right cable through the hole in the brake
hose bracket.
(6) Push both cables through the frame bracket.
NOTE: The right cable must be installed in the top
hole of the bracket.(7) Lock the left cable end fitting tabs into the
frame bracket lower hole.
(8) Install the right rear cable into the tensioner
cable bracket and lock the cable end fitting tabs into
place.
(9) Install the cables onto the cable connectors.
(10) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(11) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(12) Remove the supports and lower the vehicle.
INSTALLATION - REAR PARK BRAKE CABLE
2500/3500 SERIES WITH DRUM BRAKES
(1) Install cable guide spring.
(2) Install the brake drums.
(3) Pull back on the cable. Then push the cable
through the brake support plate hole to engage the
cable in the park brake lever.
NOTE: Pull on the cable end to ensure it is attached
to the park brake lever.
(4) Push each cable housing through the brake
support plate hole until the cable end fitting tabs
lock into place.
NOTE: Pull on the cable housing to ensure it is
locked into place.
(5) Install the right cable retainers on the axle.
The push the right cable through the hole in the
brake hose bracket.
(6) Push both cables through the frame bracket.
Push the left cable until the cable end fitting tabs
lock into place. Install the O-ring on the right cable.
NOTE: The right cable must be installed in the top
hole of the bracket and left cable in the bottom
hole.
(7) Install the cables onto the cable tensioner
bracket and install the cables into the cable connec-
tors.
(8) Install the wheel and tire assemblies.
(9) Perform park brake adjustment procedure.
(10) Remove supports and lower vehicle.
BR/BEBRAKES 5 - 39
CABLES (Continued)

(7) Using a trim stick or another suitable wide
flat-bladed tool, gently pry each of the park brake
release handle mounting bracket latch tabs away
from the retaining notches in the instrument panel
receptacle (Fig. 72).
(8) With both of the park brake release handle
mounting bracket latches released, slide the handle
and bracket assembly down and out of the instru-
ment panel receptacle.
INSTALLATION
(1) Position the park brake release handle to the
instrument panel.
(2) Slide the handle and bracket assembly up into
the instrument panel receptacle until both of the
park brake release handle mounting bracket latches
are engaged with the notches in the instrument
panel receptacle.
(3) Lower the park brake release handle and reach
under the driver side outboard end of the instrument
panel to engage the park brake release linkage rod
end with the lever on the back of the park brake
release handle.(4) Lift the park brake release handle to access
and snap the plastic retainer clip that secures the
park brake release linkage rod to the lever on the
back of the park brake release handle over the link-
age rod.
(5) Reach under the driver side outboard end of
the instrument panel to access and engage the park
brake release linkage rod end to the park brake
mechanism.
(6) Snap the plastic retainer clip that secures the
park brake release linkage rod to the park brake
mechanism on the left cowl side inner panel over the
linkage rod.
(7) Reconnect the battery negative cable.
SHOES
REMOVAL - REAR DRUM IN HAT PARK BRAKE
SHOES - 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 - REMOVAL)
(4) Remove the disc brake rotor, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL)
(5) Lockout the parking brake cable (Fig. 73).
Fig. 72 Park Brake Release Handle Remove/Install
1 - CLIP
2 - ROD
3 - MOUNTING BRACKET
4 - TRIM STICK
5 - LATCH TABS
6 - PARK BRAKE RELEASE HANDLE
Fig. 73 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
BR/BEBRAKES 5 - 41
RELEASE (Continued)