2002 DODGE RAM steering

(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Always clean the master cylinder reservoir and
caps before checking fluid level. If not cleaned, dirt
could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 19).
The correct fluid level is to the FULL indicator on
the side of the reservoir. If necessary, add fluid to the
proper level.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoir cap and empty fluid into
drain container.
(2) Clamp cylinder body in vise with brass protec-
tive jaws.
(3) Remove pins that retain reservoir to master
cylinder. Use hammer and pin punch to remove pins
(Fig. 20).
(4) Loosen reservoir from grommets with pry tool
(Fig. 21).
(5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 22).
(6) Remove old grommets from cylinder body (Fig.
23).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body (Fig. 24).
Use finger pressure to install and seat grommets.
(2) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
Fig. 19 Master Cylinder Fluid Level - Typical
1 - INDICATOR
2 - RESERVOIR
BR/BEBRAKES - BASE 5 - 15
DISC BRAKE CALIPERS (Continued)

PEDAL
DESCRIPTION
The brake booster is operated by a suspended type
brake pedal. The pedal pivots on a shaft located in a
mounting bracket attached to the dash panel. The
pedal shaft is supported by bushings in the pedal
and mounting bracket. The brake pedal is attached
to the booster push rod.
OPERATION
When the pedal is depressed, the primary booster
push rod is depressed which move the booster sec-
ondary rod. The booster secondary rod depress the
master cylinder piston.
REMOVAL
(1) Remove knee bolster, (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(2) Remove brake lamp switch, (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL).
(3) Remove switches from tabs on brake lamp
switch bracket.
(4) Remove brake lamp switch bracket bolts and
remove bracket (Fig. 25).
(5) Remove clip and washer attaching booster push
rod and slide push rod off pedal.
(6) Remove E-clip from passenger side of pedal
shaft (Fig. 26). Use flat blade screwdriver to pry clip
out of shaft groove.
(7) Push shaft toward driver side of bracket just
enough to expose opposite E-clip. Then remove E-clip
with flat blade screwdriver.(8) Push pedal shaft back and out of passenger
side of bracket (Fig. 26).
(9) Remove pedal shaft, brake pedal, wave washer
and bushings from vehicle.
INSTALLATION
(1) Replace bracket and pedal bushings if neces-
sary. Lubricate shaft bores in bracket and pedal
before installing bushings with Mopar Multi-mileage
silicone grease.
(2) Apply liberal quantity of Mopar multi-mileage
grease to pedal shaft and to pedal and bracket bush-
ings.
(3) Position brake pedal in mounting bracket.
(4) Slide pedal shaft into bracket and through
pedal from passenger side.
(5) Push pedal shaft out driver side of mounting
bracket just enough to allow installation of retaining
E-clip.
(6) Install the wave washer between the bracket
and the pedal bushing on the passenger side.
(7) Push pedal shaft back toward passenger side of
bracket and install remaining E-clip on pedal shaft.
(8) Install booster push rod on brake pedal. Secure
push rod to pedal with washer and retaining clip.
(9) Install brake lamp switch bracket and switch,
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
Fig. 25 Brake Lamp Switch Bracket
1 - PEDAL BRACKET
2 - BRAKELIGHT SWITCH BRACKET
3 - BRACKET SCREWS (2)
Fig. 26 Brake Pedal Mounting (With Automatic
Transmission)
1 - PEDAL SHAFT
2 - SHAFT RETAINING E-CLIPS (2)
3 - BRAKE PEDAL
4 - PEDAL BUSHING (2)
5 - PEDAL MOUNTING BRACKET
BR/BEBRAKES - BASE 5 - 17

EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION).
(10) Install knee bolster, (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
POWER BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER
The hydraulic booster uses hydraulic pressure from
the power steering pump. Before diagnosing a
booster problem, first verify the power steering pump
is operating properly. Perform the following checks.
²Check the power steering fluid level.
²Check the brake fluid level.
²Check all power steering hoses and lines for
leaks and restrictions.
²Check power steering pump pressure.
NOISES
The hydraulic booster unit will produce certain
characteristic booster noises. The noises may occur
when the brake pedal is used in a manner not asso-
ciated with normal braking or driving habits.
HISSING
A hissing noise may be noticed when above normal
brake pedal pressure is applied, 40 lbs. or above. The
noise will be more noticeable if the vehicle is not
moving. The noise will increase with the brake pedal
pressure and an increase of system operating temper-
ature.
CLUNK-CHATTER-CLICKING
A clunk-chatter-clicking may be noticed when the
brake pedal is released quickly, after above normal
brake pedal pressure is applied 50-100 lbs..
BOOSTER FUNCTION TEST
With the engine off depress the brake pedal several
times to discharge the accumulator. Then depress the
brake pedal using 40 lbs. of force and start the
engine. The brake pedal should fall and then push
back against your foot. This indicates the booster is
operating properly.
ACCUMULATOR LEAKDOWN
(1) Start the engine, apply the brakes and turn the
steering wheel from lock to lock. This will ensure the
accumulator is charged. Turn off the engine and let
the vehicle sit for one hour. After one hour there
should be at least two power assisted brake applica-
tion with the engine off. If the system does not retain
a charge the booster must be replaced.(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 the
booster must be replaced.
SEAL LEAKAGE
If the booster leaks from any of the seals the
booster assembly must be replaced (Fig. 27).
²INPUT ROD SEAL:Fluid leakage from rear
end of the booster.
²PISTON SEAL:Fluid leakage from vent at
front of booster.
²HOUSING SEAL:Fluid leakage between hous-
ing and housing cover.
²SPOOL VALVE SEAL:Fluid leakage near
spool plug.
²RETURN PORT FITTING SEAL:Fluid leak-
age from port fitting.
Fig. 27 Hydraulic Booster Seals
1 - PUMP
2 - GEAR
3 - INPUT SEAL
4 - HOUSING SEAL
5 - ACCUMULATOR SEAL
6 - PISTON SEAL
7 - SPOOL PLUG SEAL
8 - RETURN
5 - 18 BRAKES - BASEBR/BE
PEDAL (Continued)

HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
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. 28).
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal. (Fig. 29).
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster (Fig. 30).
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.).
BR/BEBRAKES - BASE 5 - 19
POWER BRAKE BOOSTER (Continued)

(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 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 TESTING
DISC 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
Fig. 28 Master Cylinder And Booster
1 - MASTER CYLINDER
2 - RETURN LINE
3 - LINE FROM PUMP
4 - HYDRAULIC BOOSTER
5 - LINE TO GEAR
Fig. 29 Booster Push Rod
1 - BOOSTER PUSH ROD
2 - WASHER
3 - CLIP
4 - PEDAL
Fig. 30 Booster Mounting
1 - STEERING COLUMN
2 - MOUNTING NUTS
3 - BOOSTER PEDAL ROD
4 - MOUNTING NUTS
5 - 20 BRAKES - BASEBR/BE
POWER BRAKE BOOSTER (Continued)

REMOVAL - FRONT ± 2500
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the caliper from the steering knuckle,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) and remove
caliper adapter assembly (Fig. 34).
NOTE: Do not allow brake hose to support caliper
adapter assembly.
(4) Remove the rotor from the hub/bearing wheel
studs.
REMOVAL - FRONT - 3500
(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
INSTALLATION - REAR
(1) Install the hub to the rotor. Tighten the bolts to
128 N´m (95 ft. lbs.) (Fig. 35).
(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. 36).
(6) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.
Fig. 34 Caliper Adapter Assembly
1 - KNUCKLE
2 - CALIPER
3 - ROTOR
Fig. 35 ROTOR TO HUB
1 - Hub Bolts
2 - Socket
Fig. 36 ROTOR INSTALLED
5 - 22 BRAKES - BASEBR/BE
ROTORS (Continued)

INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Install master cylinder on the booster mount-
ing studs.
(2) Install mounting nuts and tighten to 23 N´m
(17 ft. lbs.).
(3) Install brake lines and tighten to 19-23 N´m
(170-200 in. lbs.).
(4) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE)
PARKING BRAKE
DESCRIPTION
The parking brakes are operated by a system of
cables and levers attached to a primary and second-
ary shoe positioned within the drum section of the
rotor.
The drum-in-hat design utilizes an independent set
of shoes to park the vehicle (Fig. 51).
OPERATION
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.
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. 52)
from the arm on the pedal assembly.
Fig. 50 Master Cylinder
1 - MOUNTING NUT
2 - MOUNTING NUT
3 - BRAKE LINES
4 - MASTER CYLINDER
Fig. 51 SHOES REMOVAL
1 - PARK BRAKE SHOES
2 - ADJUSTER
3 - RETURN SPRINGS
4 - SPLASH SHIELD
5 - HOLD DOWNS
5 - 28 BRAKES - BASEBR/BE
MASTER CYLINDER (Continued)

(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.
CABLES
REMOVAL
REMOVAL - REAR PARK BRAKE CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 53).
(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. 54).
(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.
Fig. 52 Parking Brake Pedal Assembly
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
Fig. 53 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 54 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
BR/BEBRAKES - BASE 5 - 29
PEDAL (Continued)