2002 DODGE RAM brake

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
NOTE: For New Vehicle Preparation
information, see the separate
publication, 81-170-00003.

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 7) and (Fig. 8).
INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
6 INTRODUCTIONBR/BE
INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS (Continued)

TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 7)and
(Fig. 8).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
Fig. 7 Jumper Cable Clamp ConnectionsÐGas
Engine
1 - NEGATIVE OR GROUND CABLE CONNECTION
2 - POSITIVE CABLE CONNECTION
3 - BATTERY
Fig. 8 Jumper Cable Clamp ConnectionsÐDiesel
Engine
1 - POSITIVE CABLE CONNECTION
2 - BATTERY
3 - NEGATIVE OR GROUND CABLE CONNECTION
0 - 8 LUBRICATION & MAINTENANCEBR/BE
JUMP STARTING (Continued)

TOWING
STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all vehicles.
When towing a 4WD vehicle using a wheel-lift towing
device, use tow dollies under the opposite end of the
vehicle. A vehicle with flat-bed device can also be
used to transport a disabled vehicle (Fig. 12).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
Fig. 11 Front Lift Pad Location
1 - SHIPPING TIE DOWN SLOT
2 - CROSSMEMBER BOLT ACCESS HOLE
3 - LIFTARM
4 - LIFT PAD EXTENSION
5 - FRAME RAIL
Fig. 12 Tow Vehicles With Approved Equipment
1 - SLING TYPE
2 - WHEEL LIFT
3 - FLAT BED
0 - 10 LUBRICATION & MAINTENANCEBR/BE
HOISTING (Continued)

SPECIAL TOOLS
INDEPENDENT FRONT SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the caliper adapter bolts from the
steering knuckle and remove caliper adapter assem-
bly (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/DISC BRAKE CALIPERS - REMOVAL).
NOTE: Do not allow brake hose to support caliper
adapter assembly.
(4) Remove the rotor from the hub/bearing wheel
studs.
(5) Remove the hub/bearing nut (Fig. 3) and slide
the hub/bearing off the spindle.On 3500 HD models
the hub spindle shaft must removed (Fig. 4).
CAUTION: The hub/bearing nut can not be re-used.
INSTALLATION
(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) Slide the hub/bearing onto the spindle.On 3500
HD slide the spindle stub shaft into the hub/bearing
and tighten.(3) Install thenewhub/bearing nut and tighten
to:
²2500/3500: 380 N´m (280 ft lbs.)
(4) Install the rotor onto hub/bearing wheel studs.
(5) Install the caliper adapter assembly (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION), and tighten
adapter bolts to:
²2500/3500: 285 N´m (210 ft lbs.)
(6) Install the wheel and tire assembly and lower
the vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS
- STANDARD PROCEDURE).
(7) Apply brakes several times to seat brake shoes.
Be sure to obtain firm pedal before moving vehicle.
Remover, Tie Rod End MB-990635
Puller Tie Rod C-3894-A
Fig. 3 Caliper Adapter Assembly
1 - HUB/BEARING
2 - SPINDLE
Fig. 4 SPINDLE STUB SHAFT
1 - Hub/Bearing
2 - Knuckle
3 - Spindle Stub Shaft
BR/BEFRONT - 2WD 2 - 9
FRONT - 2WD (Continued)

KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor, (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the cotter pin and nut from the tie-rod
end. Remove the tie rod end from the knuckle with
Puller C-3894-A.
(5) Remove the cotter pins and nuts from the
upper and lower ball joints. Separate upper ball joint
from knuckle with remover MD-990635. Separate
lower ball joint with remover C-4150A and remove
knuckle.
INSTALLATION
(1) Position the knuckle on the ball joints and
install the ball joint nuts.
(2) Tighten the upper ball joint nut to 81 N´m (60
ft. lbs.) and install cotter pin.
(3) Tighten the lower ball joint nut to:
²149 N´m (110 ft. lbs.) Install the cotter pin.
(4) Install the tie rod end on the steering knuckle
and tighten the nut to 108 N´m (80 ft. lbs.). Install
cotter pin.
(5) Install the brake rotor and caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(6) Install wheel and tire assembly (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and lower vehicle.
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
(1) Raise the front of the vehicle. Place safety floor
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
NOTE: The upper suspension arms must not be in
maximum rebound position.
(2) Remove the tire and wheel assembly.
(3) Mount a dial indicator solidly under the lower
suspension arm.
(4) Position indicator plunger against the bottom
of the steering knuckle lower ball joint boss.NOTE: The dial Indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss.
(5) Position a pry bar over the top of the upper
suspension arm and under the pivot bar of the upper
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen-
sion arm and on top of the frame rail. Pry up on the
upper suspension arm and record the dial indicator
reading.
(7) If the travel exceeds 0.8 mm (0.030 in.) replace
the suspension arm.
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from lower sus-
pension arm.
(6) Support the lower suspension arm outboard
end with jack. Place a jack under the arm in the
front of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
(10) Remove bolts mounting suspension arm to
crossmember and remove arm.
INSTALLATION
(1) Position the suspension arm on the crossmem-
ber and install the bolts and nuts snug.
(2) Install the rubber isolator on top of the spring.
Position the spring into upper spring seat.
(3) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(4) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(5) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
2 - 10 FRONT - 2WDBR/BE

²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(6) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(7) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(8) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(9) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the support and lower the vehicle.
(11) Tighten the suspension arm crossmember
nuts to 169 N´m (125 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Raise and support vehicle.
(2) Remove shock upper nut and remove retainer
and grommet.
(3) Remove lower mounting bolt from suspension
arm and remove shock (Fig. 5).
INSTALLATION
(1) Extend shock fully, install retainer and grom-
met on top of shock absorber. Check grommets and
retainer for wear.(2) Guide shock up through upper suspension arm
bracket. Install top grommet, retainer and nut.
Tighten nut to 54 N´m (40 ft. lbs.).
(3) Align bottom end of shock into lower suspen-
sion arm and install mounting bolt. Tighten bolt to
142 N´m (105 ft. lbs.).
(4) Remove support and lower vehicle.
SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from the lower
suspension arm.
(6) Support the lower suspension arm outboard
end with a jack. Place a jack under the arm in front
of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
Fig. 5 Shock
1 - SHOCK
2 - JOUNCE BUMPER
BR/BEFRONT - 2WD 2 - 11
LOWER CONTROL ARM (Continued)

INSTALLATION
(1) Install the rubber isolator on top of the spring.
Position the spring into the upper spring seat.
(2) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(3) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(4) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(5) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(6) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(7) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(8) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Remove the support and lower the vehicle.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the link nuts, retainers and grommets
from lower suspension arm and stabilizer bar (Fig.
7).
(3) Remove the stabilizer bar clamps from the
frame rails. Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 54 N´m (40 ft. lbs.).
(2) Install links on stabilizer bar and lower sus-
pension arm. Install grommets, retainers and nuts.
Tighten nuts to 37 N´m (27 ft. lbs.).
(3) Remove the supports and lower the vehicle.
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to
lightly contact the floor (vehicle weight relieved from
the tire).
(2) Mount a dial indicator solidly on the upper sus-
pension arm.
(3) Position the indicator plunger against the
upper ball stud boss of the steering knuckle.
(4) Grasp the top of the tire and apply force in and
out. Look for movement at the ball joint between the
upper suspension arm and steering knuckle.
(5) If lateral movement is greater than 0.8 mm
(0.030 in.), replace the suspension arm.
Fig. 6 Coil Spring
1 - COIL SPRING
2 - RUBBER ISOLATER
Fig. 7 STABILIZER BAR
1 - STABILIZER BAR
2 - GROMMET
3 - GROMMET
4 - LINK
2 - 12 FRONT - 2WDBR/BE
SPRING (Continued)