2003 DODGE RAM wheel

(2) Install the caliper adapter (Fig. 50) (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(3) Install the caliper adapter bolts (Fig. 50) and
tighten the mounting bolts to 135 N´m (100 ft.lbs).
(4) Install the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Lower the vehicle.
INSTALLATION - 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 the 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:
(4) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE) and lower the vehicle.
(5) Apply the brakes several times to seat brake
pads. Be sure to obtain firm pedal before moving
vehicle.
SUPPORT PLATE
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(5) Remove the axle shaft (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(7) Remove the parking brake cable from the
brake lever.
(8) Remove the bolts attaching the support plate to
the axle and remove the support plate (Fig. 54).
INSTALLATION
(1) Install support plate on axle flange (Fig. 55).
Tighten attaching bolts to 115 N´m (85 ft. lbs.).
(2) Install parking brake cable in the brake lever.
(3) Install the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION). (Fig. 55).
(4) Install axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - INSTALLATION).
(5) Adjust brake shoes to drum with brake gauge
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS).
Fig. 52 FRONT ROTOR
1 - ROTOR
2 - HUB/BEARING
Fig. 53 8 LUG ROTOR ASSEMBLY
1 - SPRING
2 - SHOCK
3 - UPPER AND LOWER SUSPENSION ARMS
4 - DISC BRAKE CALIPER
5 - DISC BRAKE CALIPER ADAPTER
6 - ROTOR
DRBRAKES - BASE 5 - 29
ROTORS (Continued)

(6) Install the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION).
(7) Install the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(8) Install the caliper (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(9) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
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. 56).
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.
Fig. 54 SUPPORT PLATE
1 - SUPPORT PLATE
2 - MOUNTING STUDS
Fig. 55 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
Fig. 56 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
5 - 30 BRAKES - BASEDR
SUPPORT PLATE (Continued)

(6) Install the right cable to the front cable.
(7) Adjust the brake cable at the equalizer and
using the adjuster nut.
INSTALLATION - LEFT REAR CABLE
(1) Install the brake cable to the brake lever (Fig.
61).
(2) Install the brake cable to the frame bracket.
(3) Install the left brake cable to the equalizer.
(4) Adjust the brake cable at the equalizer and
adjuster nut.
SHOES
REMOVAL
(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. 63).
(6) Disengage the park brake cable from behind
the rotor assembly to allow easier disassembly of the
park brake shoes (Fig. 64).
(7) Remove the axleshaft (Fig. 65) (Refer to 3 -
DIFFERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/
AXLE SHAFTS - REMOVAL).
(8) Disassemble the rear park brake shoes (Fig.
56).
CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including
the support plate 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 support plate
with fine sandpaper.
INSPECTION - REAR DRUM IN HAT BRAKE
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
Fig. 62 PARKING BRAKE CABLE
1 - SUPPORT PLAT
2 - CABLE
3 - LEVER
Fig. 63 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 64 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
DRBRAKES - BASE 5 - 33
CABLES (Continued)

replaced and the drum checked for runout or taper
(Fig. 66).
Inspect the adjuster screw assembly. Replace the
assembly if the star wheel or threads are damaged,
or the components are severely rusted or corroded
(Fig. 66).
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. 66).
INSTALLATION
NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake foot pedal.
(1) Reassemble the rear park brake shoes (Fig.
56).
(2) Install the axleshaft (Fig. 65) (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/
AXLE SHAFTS - INSTALLATION).
(3) Install the park brake cable to the lever behind
the support plate.
(4) Unlock the park brake cable.
(5) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).(6) Install the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(7) Adjust the rear brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Lower the vehicle.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from the axleshaft (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
Fig. 65 AXLE SHAFT
1 - AXLE SHAFT
2 - SUPPORT PLATE
3 - CALIPER
4 - PARK BRAKE SHOE ASSEMBLY
Fig. 66 PARK BRAKE SHOES
5 - 34 BRAKES - BASEDR
SHOES (Continued)

NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent,accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
67).
(6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 68).
(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 69).(8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes.
(9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on the axleshaft (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - INSTALLATION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
Fig. 67 Measuring Park Brake Drum Diameter
Fig. 68 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 69 Setting Gauge To Park Brake Shoe
Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
DRBRAKES - BASE 5 - 35
SHOES (Continued)

NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake foot pedal.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
ADJUSTMENT - WITH ADJUSTING TOOL
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.
(1) Be sure parking brake lever is fully released.
(2) Raise vehicle so rear wheels can be rotated
freely.
(3) Remove plug from each access hole in brake
support plates.
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool through support plate
access hole and engage tool in teeth of adjusting
screw star wheel (Fig. 70).
(6) Rotate adjuster screw star wheel (move tool
handle upward) until slight drag can be felt when
wheel is rotated.
(7) Push and hold adjuster lever away from star
wheel with thin screwdriver.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.(9) Repeat adjustment at opposite wheel. Be sure
adjustment is equal at both wheels.
(10) Install support plate access hole plugs.
(11) Adjust parking brake cable and lower vehicle.
(12) Depress park brake pedal and make sure park
brakes hold the vehicle staionary.
(13) Release park brake pedal.
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 release rod (Fig. 71) 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.) (Fig. 72).
(3) Install the park brake release rod.
(4) Connect the front cable to the arm on the pedal
assembly.
Fig. 70 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRINGFig. 71 PARKING BRAKE PEDAL
1 - RELEASE ROD
2 - PEDAL ASSEMBLY
5 - 36 BRAKES - BASEDR
SHOES (Continued)

(5) Tighten the front cable grommet to the floor-
pan and the cable retainer, roll the carpet back.
(6) Connect the wires to the brake lamp switch.
(7) Install the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(8) Raise the vehicle.
(9) Adjust the parking brake cable tensioner (Refer
to 5 - BRAKES/PARKING BRAKE/CABLE TEN-
SIONER - ADJUSTMENTS).
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT
NOTE: Tensioner adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid
faulty park brake operation.
(1) Raise the vehicle.
(2) Back off the cable tensioner adjusting nut to
create slack in the cables.
(3) Remove the rear wheel/tire assemblies. Then
remove the brake rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(4) Verify the brakes are in good condition and
operating properly.
(5) Verify the park brake cables operate freely and
are not binding, or seized.(6) Check the rear brake shoe adjustment with
standard brake gauge (Refer to 5 - BRAKES/PARK-
ING BRAKE/SHOES - ADJUSTMENTS).
(7) Install the rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION) and verify that the rotors rotate freely
without drag.
(8) Install the wheel/tire assemblies, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Lower the vehicle enough for access to the park
brake foot pedal. Then fully apply the park brakes.
NOTE: Leave park brakes applied until adjustment
is complete.
(10) Raise the vehicle again.
(11) Mark the tensioner rod 6.35 mm (1/4 in.) from
edge of the tensioner (Fig. 73).
(12) Tighten the adjusting nut on the tensioner rod
until the mark is no longer visible.
CAUTION: Do not loosen, or tighten the tensioner
adjusting nut for any reason after completing
adjustment.
(13) Lower the vehicle until the rear wheels are
15-20 cm (6-8 in.) off the shop floor.
(14) Release the park brake foot pedal and verify
that rear wheels rotate freely without drag. Then
lower the vehicle.
Fig. 72 PARKING BRAKE ASSEMBLY
1 - PEDAL ASSEMBLY
2 - MOUNTING NUT
Fig. 73 Adjustment Mark
1 - TENSIONER CABLE BRACKET
2 - TENSIONER
3 - CABLE CONNECTOR
4 - 6.35mm
(1/4 IN.)
5 - ADJUSTER NUT
DRBRAKES - BASE 5 - 37
PEDAL (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................39
OPERATION...........................39
STANDARD PROCEDURE - ABS BRAKE
BLEEDING...........................40
SPECIFICATIONS
TORQUE CHART......................40
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................41
INSTALLATION.........................42
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
ANTILOCK...........................42
REMOVAL.............................42
INSTALLATION.........................43
TONE WHEEL
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR......................43HYDRAULIC/MECHANICAL
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............43
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............43
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................44
INSTALLATION.........................44
R WA L VA LV E
DESCRIPTION.........................44
OPERATION...........................44
REMOVAL.............................45
INSTALLATION.........................45
BRAKES - ABS
DESCRIPTION
The antilock brake system (ABS) is an electroni-
cally operated, three channel brake control system.
The vehicle has Electronic Variable Brake Propor-
tioning (EVBP) designed into the system which elim-
inates the combination/proportioning valve.
The system is designed to prevent wheel lockup
and maintain steering control during braking. Pre-
venting lockup is accomplished by modulating fluid
pressure to the wheel brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem. The ABS elec-
trical system is separate from other electrical circuits
in the vehicle. A specially programmed controller
antilock brake unit operates the system components.
ABS system major components include:
²Controller Antilock Brakes (CAB)
²Hydraulic Control Unit (HCU)
²Wheel Speed Sensors (WSS)
²ABS Warning Light
OPERATION
Battery voltage is supplied to the CAB. The CAB
performs a system initialization procedure at start
up. A check of the ABS motor is performed at 15
miles per hour. Initialization consists of a static and
dynamic self check of system electrical components.
The static and dynamic checks occurs at ignition
start up. During the dynamic check, the CAB briefly
cycles solenoids to verify operation. An audible noise
may be heard during this self check. This noise
should be considered normal. The ABS motor and
pump are then checked at a speed of 15 mile per
hour.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
The CAB monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the CAB will not activate any ABS components as
long as sensor inputs indicate normal braking.
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
DRBRAKES - ABS 5 - 39