2002 DODGE RAM brake pads

(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 37 N´m (27 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 88 N´m (65 ft. lbs.).
(11) Install ABS wheel speed sensors, if equipped.
Refer to 5 Brakes for procedures.
(12) Install rotors and brake calipers, refer to 5
Brakes for procedures.
(13) Connect the vent hose to the tube fitting.
(14) Connect vacuum hose and electrical connector
to disconnect housing.
(15) Install front propeller shaft.
(16) Check and add differential lubricant, if neces-
sary. Refer to Lubricant Specifications for lubricant
requirements.
(17) Install wheel and tire assemblies.
(18) Remove supports and lower the vehicle.
(19) Tighten upper suspension arm nuts at axle to
121 N´m (89 ft. lbs.). Tighten upper suspension arm
nuts at frame to 84 N´m (62 ft. lbs.).
(20) Tighten lower suspension arm nuts at axle to
84 N´m (62 ft. lbs.). Tighten the lower suspension
arm nuts at frame to 119 N´m (88 ft. lbs.).
(21) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(22) Check front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched sets
only. The identifying numbers for the ring and pinion
gear are etched into the face of each gear (Fig. 3). A
plus (+) number, minus (±) number or zero (0) is etched
into the face of the pinion gear. This number is the
amount (in thousandths of an inch) the depth varies
from the standard depth setting of a pinion etched with
a (0). The standard setting from the center line of the
ring gear to the back face of the pinion is 127 mm (5.00
in.). The standard depth provides the best gear tooth
contact pattern. Refer to Backlash and Contact Pattern
in this section for additional information.
Compensation for pinion depth variance is
achieved with a select shim/slinger. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 4).
Fig. 3 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 4 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/SLINGER
2 - DIFFERENTIAL BEARING SHIM
BR/BEFRONT AXLE - 248FBI 3 - 19
FRONT AXLE - 248FBI (Continued)

BRAKE PADS/SHOES
REMOVAL
REMOVAL - REAR.....................23
REMOVAL - FRONT....................24
INSTALLATION
INSTALLATION - REAR.................25
INSTALLATION - FRONT................26
MASTER CYLINDER
DESCRIPTION.........................26
OPERATION...........................26
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........26
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................27
REMOVAL.............................27
INSTALLATION.........................28
PARKING BRAKE
DESCRIPTION.........................28
OPERATION...........................28
PEDAL
REMOVAL.............................28
INSTALLATION.........................29CABLES
REMOVAL
REMOVAL - REAR PARK BRAKE CABLE . . . 29
REMOVAL - FRONT PARKING BRAKE
CABLE..............................29
INSTALLATION
INSTALLATION - REAR PARK BRAKE
CABLE..............................30
INSTALLATION - FRONT PARKING BRAKE
CABLE..............................30
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT........................30
RELEASE HANDLE
REMOVAL.............................31
INSTALLATION.........................32
SHOES
REMOVAL.............................32
INSTALLATION.........................32
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 33
BRAKES - BASE
SPECIFICATIONS
BASE BRAKE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Front/Rear Disc Brake
Caliper
TypeDual Piston Sliding
Front Disc Brake Caliper
Piston Diameter HD56 mm (2.00 in.)
Front Disc Brake Rotor 326.5ý36 mm
(12.5ý1.5 in.)
Front/Rear Disc Brake
Rotor
Max. Runout0.127 mm (0.005 in.)
Front/Rear Disc Brake
Rotor
Max. Thickness Variation0.025 mm (0.001 in.)
DESCRIPTION SPECIFICATION
Minimum Front Rotor
Thickness33.90 mm (1.334 in.)
Mininium Rear Rotor
Thickness28.39 mm (1.117 in)
Rear Disc Brake Caliper
25002x45 mm (1.77 in)
Rear Disc Brake Caliper
35002x51 mm (2.00 in)
Rear Disc Brake Rotor
2500/3500323.5x30 mm (1.18 in)
Brake Booster
Type
2500 Gasoline EnginesVacuum Dual Diaphragm
Brake Booster
Type
All 3500/
2500 Diesel Engines
OnlyHydraulic
5 - 2 BRAKES - BASEBR/BE

INSTALLATION - FRONT ± 2500
(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 - FRONT - 3500
(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.
BRAKE PADS/SHOES
REMOVAL
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 hose to support caliper
assembly.
(5) Remove the caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) and then tilt the top up and off the cal-
iper adapter (Fig. 37).
(6) Remove inboard brake shoe from the caliper
adapter (Fig. 38).
(7) Remove outboard brake shoe from caliper
adapter (Fig. 39).(8) Remove the anti-rattle springs from the caliper
adapter (Fig. 40) and (Fig. 41).
NOTE: Anti-rattle springs are not interchangeable.
Fig. 37 ROTOR / PADS/ CALIPER
1 - ROTOR
2 - BRAKE SHOES
3 - DISC BRAKE CALIPER
Fig. 38 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
BR/BEBRAKES - BASE 5 - 23
ROTORS (Continued)

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
- REMOVAL).
(5) Remove caliper by tilting the top up and off the
caliper adapter (Fig. 42).NOTE: Do not allow brake hose to support caliper
assembly.
(6) Remove inboard brake shoe from the caliper
adapter (Fig. 43).
(7) Remove outboard brake shoe from caliper
adapter (Fig. 44).
(8) Remove the anti-rattle springs from the caliper
adapter (Fig. 45) and (Fig. 46).
NOTE: Anti-rattle springs are not interchangeable.
Fig. 39 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
Fig. 40 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 41 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
Fig. 42 Caliper
1 - CALIPER
2 - CALIPER ADAPTER
5 - 24 BRAKES - BASEBR/BE
BRAKE PADS/SHOES (Continued)

INSTALLATION
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. 43 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 44 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
Fig. 45 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 46 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
BR/BEBRAKES - BASE 5 - 25
BRAKE PADS/SHOES (Continued)

(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 and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(9) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(10) Top off master cylinder fluid level.
INSTALLATION - FRONT
(1) Bottom pistons in caliper bore with C-clamp.
Place an old brake shoe between a C-clamp and cal-
iper piston.
(2) Clean caliper mounting adapter and anti-rattle
springs.
(3) Lubricate anti-rattle springs with Mopar brake
grease.
(4) Install anti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
(5) Install inboard brake shoe in adapter.
(6) Install outboard brake shoe in adapter.
(7) Tilt the bottom of the caliper over rotor and
under adapter. Then push the top of the caliper down
onto the adapter.
(8) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(9) Install wheel and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(10) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(11) Top off master cylinder fluid level.
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. 47).
(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.
5 - 26 BRAKES - BASEBR/BE
BRAKE PADS/SHOES (Continued)