brake pads DODGE RAM 2001 Service Repair Manual

(8) Disconnect the stabilizer bar links at the axle
brackets.
(9) Disconnect the shock absorbers from axle
brackets.
(10) Disconnect the track bar from the axle
bracket.
(11) Disconnect the tie rod and drag link from the
steering knuckles.
(12) Position the axle with a suitable lifting device
under the axle assembly.
(13) Secure axle to lifting device.
(14) Mark suspension alignment cams for installa-
tion reference.
(15) Disconnect the upper and lower suspension
arms from the axle bracket.
(16) Lower the axle. The coil springs will drop
with the axle.
(17) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur. Rubber bushings must never
be lubricated.
(1) Support the axle on a suitable lifting device.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install the springs, retainer clip and bolts.
(5) Raise the axle and align it with the spring
pads.
(6) Position the 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 the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install the shock absorber and tighten bolts to
121 N´m (89 ft. lbs.) torque.
(9) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 37 N´m (27 ft. lbs.)
torque.
(10) Install the drag link and tie rod to the steer-
ing knuckles and tighten the nuts to 88 N´m (65 ft.
lbs.) torque.
(11) Install the ABS wheel speed sensors, if
equipped. Refer to group 5, Brakes, for proper proce-
dures.
(12) Install the brake calipers and rotors. Refer to
Group 5, Brakes, for proper 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 in this section
for lubricant requirements.
(17) Install the wheel and tire assemblies.
(18) Remove the supports and lower the vehicle.
(19) Tighten the upper suspension arm nuts at
axle to 121 N´m (89 ft. lbs.) torque. Tighten the
upper suspension arm nuts at frame to 84 N´m (62 ft.
lbs.) torque.
(20) Tighten the lower suspension arm nuts at
axle to 84 N´m (62 ft. lbs.) torque. Tighten the lower
suspension arm nuts at frame to 119 N´m (88 ft. lbs.)
torque.
(21) Tighten the track bar bolt at the axle bracket
to 176 N´m (130 ft. lbs.) torque.
(22) Check the 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.
4). 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 cen-
ter line of the ring gear to the back face of the pinion
is 109.5 mm (4.312 in.). The standard depth provides
the best gear tooth contact pattern. Refer to Back-
lash and Contact Pattern in this section for addi-
tional information.
Compensation for pinion depth variance is
achieved with a select shim/oil baffle. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 5).
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
BR/BEFRONT AXLE - 216FBI 3 - 17
FRONT AXLE - 216FBI (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheels and tires.
(3) Remove the brake calipers and rotors. Refer to
Group 5, Brakes, for proper procedures.
(4) Remove ABS wheel speed sensors, if equipped.
Refer to Group 5, Brakes, for proper procedures.
(5) Disconnect the axle vent hose.
(6) Disconnect vacuum hose and electrical connec-
tor at disconnect housing.
(7) Remove the front propeller shaft.
(8) Disconnect the stabilizer bar links at the axle
brackets.
(9) Disconnect the shock absorbers from axle
brackets.
(10) Disconnect the track bar from the axle
bracket.
(11) Disconnect the tie rod and drag link from the
steering knuckles.
(12) Position the axle with a suitable lifting device
under the axle assembly.
(13) Secure axle to lifting device.
(14) Mark suspension alignment cams for installa-
tion reference.
(15) Disconnect the upper and lower suspension
arms from the axle bracket.
(16) Lower the axle. The coil springs will drop
with the axle.
(17) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur. Rubber bushings must never
be lubricated.
(1) Support the axle on a suitable lifting device.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install the springs, retainer clip and bolts.
(5) Raise the axle and align it with the spring
pads.
(6) Position the 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 the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install the shock absorber and tighten bolts to
121 N´m (89 ft. lbs.) torque.(9) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 37 N´m (27 ft. lbs.)
torque.
(10) Install the drag link and tie rod to the steer-
ing knuckles and tighten the nuts to 88 N´m (65 ft.
lbs.) torque.
(11) Install the ABS wheel speed sensors, if
equipped. Refer to group 5, Brakes, for proper proce-
dures.
(12) Install the brake calipers and rotors. Refer to
Group 5, Brakes, for proper 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 in this section
for lubricant requirements.
(17) Install the wheel and tire assemblies.
(18) Remove the supports and lower the vehicle.
(19) Tighten the upper suspension arm nuts at
axle to 121 N´m (89 ft. lbs.) torque. Tighten the
upper suspension arm nuts at frame to 84 N´m (62 ft.
lbs.) torque.
(20) Tighten the lower suspension arm nuts at
axle to 84 N´m (62 ft. lbs.) torque. Tighten the lower
suspension arm nuts at frame to 119 N´m (88 ft. lbs.)
torque.
(21) Tighten the track bar bolt at the axle bracket
to 176 N´m (130 ft. lbs.) torque.
(22) Check the 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.
4). 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 cen-
ter 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 Back-
lash and Contact Pattern in this section for addi-
tional information.
Compensation for pinion depth variance is
achieved with a select shim/oil baffle. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 5).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
3 - 50 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE
SPECIFICATIONS.........................2
SPECIAL TOOLS..........................4
HYDRAULIC/MECHANICAL
DESCRIPTION............................4
WARNING.............................5
DIAGNOSIS AND TESTING..................5
BASE BRAKE SYSTEM...................5
STANDARD PROCEDURE...................7
MANUAL BLEEDING.....................7
PRESSURE BLEEDING...................8
BRAKE LINES
STANDARD PROCEDURE...................8
DOUBLE INVERTED FLARING..............8
ISO FLARING...........................8
COMBINATION VALVE
DESCRIPTION............................9
OPERATION.............................9
DIAGNOSIS AND TESTING..................9
COMBINATION VALVE....................9
REMOVAL..............................10
INSTALLATION...........................10
DISC BRAKE CALIPERS
REMOVAL..............................10
DISASSEMBLY...........................11
CLEANING..............................12
INSPECTION............................12
ASSEMBLY.............................12
INSTALLATION...........................13
FLUID
DIAGNOSIS AND TESTING.................14
BRAKE FLUID CONTAMINATION...........14
STANDARD PROCEDURE..................14
BRAKE FLUID LEVEL....................14
SPECIFICATIONS........................15
FLUID RESERVOIR
REMOVAL..............................15
INSTALLATION...........................15
PEDAL
DESCRIPTION...........................16
OPERATION.............................16
REMOVAL..............................16
INSTALLATION...........................17
POWER BRAKE BOOSTER
DIAGNOSIS AND TESTING.................17
HYDRAULIC BOOSTER..................17
STANDARD PROCEDURE..................19
POWER BRAKE BOOSTER...............19
REMOVAL..............................19INSTALLATION...........................20
ROTORS
DIAGNOSIS AND TESTING.................20
DISC BRAKE ROTOR....................20
REMOVAL..............................21
INSTALLATION...........................22
BRAKE PADS/SHOES
REMOVAL..............................23
INSTALLATION...........................26
MASTER CYLINDER
DESCRIPTION...........................29
OPERATION.............................29
DIAGNOSIS AND TESTING.................29
MASTER CYLINDER/POWER BOOSTER.....29
STANDARD PROCEDURE..................30
MASTER CYLINDER BLEEDING...........30
REMOVAL..............................30
INSTALLATION...........................30
WHEEL CYLINDERS
REMOVAL..............................31
DISASSEMBLY...........................31
CLEANING..............................31
INSPECTION............................31
ASSEMBLY.............................31
INSTALLATION...........................32
SUPPORT PLATE
REMOVAL..............................32
INSTALLATION...........................32
DRUM
DESCRIPTION...........................32
OPERATION.............................32
DIAGNOSIS AND TESTING.................33
BRAKE DRUM.........................33
STANDARD PROCEDURE..................33
BRAKE DRUM MACHINING...............33
CLEANING..............................33
INSPECTION............................33
ADJUSTMENTS..........................34
PARKING BRAKE
DESCRIPTION...........................35
OPERATION.............................36
PEDAL
REMOVAL..............................36
INSTALLATION...........................36
CABLES
REMOVAL..............................37
INSTALLATION...........................38
CABLE TENSIONER
ADJUSTMENTS..........................40
BR/BEBRAKES 5 - 1

BRAKE PADS/SHOES
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. 35).
(6) Remove inboard brake shoe from the caliper
adapter (Fig. 36).
(7) Remove outboard brake shoe from caliper
adapter (Fig. 37).
(8) Remove the anti-rattle springs from the caliper
adapter (Fig. 38) and (Fig. 39).
NOTE: Anti-rattle springs are not interchangeable.
Fig. 35 ROTOR / PADS/ CALIPER
1 - Rotor
2 - Brake Shoes
3 - Disc Brake Caliper
Fig. 36 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 37 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
BR/BEBRAKES 5 - 23

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. 40).
NOTE: Do not allow brake hose to support caliper
assembly.
(6) Remove inboard brake shoe from the caliper
adapter (Fig. 41).(7) Remove outboard brake shoe from caliper
adapter (Fig. 42).
(8) Remove the anti-rattle springs from the caliper
adapter (Fig. 43) and (Fig. 44).
NOTE: Anti-rattle springs are not interchangeable.
Fig. 38 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 39 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
Fig. 40 Caliper
1 - CALIPER
2 - CALIPER ADAPTER
Fig. 41 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
5 - 24 BRAKESBR/BE
BRAKE PADS/SHOES (Continued)

REMOVAL - REAR BRAKE SHOES-11 inch
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove clip nuts securing brake drum to wheel
studs.
(4) Remove drum. If drum is difficult to remove,
remove rear plug from access hole in support plate.
Back-off self adjusting by inserting a thin screw-
driver into access hole and push lever away from
adjuster screw star wheel. Then insert an adjustertool into brake adjusting hole rotate adjuster star
wheel to retract brake shoes.
(5) Vacuum brake components to remove brake lin-
ing dust.
(6) Remove shoe return springs with brake spring
plier tool (Fig. 45).
Fig. 42 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
Fig. 43 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 44 Bottom Anti-Rattle Spring
1 - ANTI-RATTLE SPRING
2 - CALIPER ADAPTER
Fig. 45 Shoe Return Springs
1 - SHOE RETURN SPRING
2 - SPECIAL TOOL (REMOVING AND INSTALLING)
3 - SHOE RETURN SPRING
4 - ADJUSTER CABLE
5 - LEVER SPRING
6 - ADJUSTER LEVER
7 - SHOE TO SHOE SPRING
8 - ANTI-RATTLE SPRING
BR/BEBRAKES 5 - 25
BRAKE PADS/SHOES (Continued)

(7) Remove adjuster cable. Slide cable eye off
anchor pin. Then unhook and remove cable from
adjuster lever.
(8) Remove cable guide from secondary shoe and
anchor plate from anchor pin.
(9) Remove adjuster lever. Disengage lever from
spring by sliding lever forward to clear pivot and
work lever out from under spring.
(10) Remove adjuster lever spring from pivot.
(11) Disengage and remove shoe to shoe spring
from brake shoes.
(12) Disengage and remove adjuster screw assem-
bly from brake shoes.
(13) Remove brake shoe retainers, springs (Fig.
46).
(14) Remove secondary brake shoe from support
plate.
(15) Remove strut and spring (Fig. 46).
(16) Remove parking brake lever retaining clip
from the secondary shoe and remove the lever.
(17) Remove primary shoe from support plate.
(18) Disengage parking brake lever from parking
brake cable.
(19) Remove parking brake cable guide spring.
REMOVAL - 12 1/8 INCH
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.(3) Remove clip nuts securing brake drum to wheel
studs.
(4) Remove brake drum.
(5) Vacuum brake components to remove brake lin-
ing dust.
(6) Unhook adjusting lever return spring from
lever.
(7) Remove lever and return spring from lever
pivot pin.
(8) Unhook adjuster lever from adjuster cable
assembly.
(9) Remove shoe-to-shoe upper spring (Fig. 47).
(10) Remove shoe hold-down springs (Fig. 48).
(11) Disconnect parking brake cable from parking
brake lever.
(12) Remove shoe-to-shoe lower spring and
adjuster assembly .
(13) Remove brake shoes (Fig. 49).
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. 46 Shoe Retainers, Springs and Pins
1 - SECONDARY SHOE AND LINING
2 - STRUT AND SPRING
3 - SPRING
4 - PIN
5 - RETAINER
6 - PRIMARY SHOE AND LINING
7 - TOOL C-4070
Fig. 47 Upper Spring
5 - 26 BRAKESBR/BE
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.
INSTALLATION - REAR BRAKE SHOES-11 inch
(1) Clean and inspect individual brake compo-
nents, (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DRUM - CLEANING).
(2) Lubricate anchor pin and brake shoe contact
pads on support plate with high temperature grease
or Lubriplate (Fig. 50).
Fig. 48 Shoe Hold-Down Springs
Fig. 49 Brake Shoe Removal
Fig. 50 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
BR/BEBRAKES 5 - 27
BRAKE PADS/SHOES (Continued)

(3) Lubricate adjuster screw socket, nut, button
and screw thread surfaces with grease or Lubriplate.
(4) Install parking brake lever to the secondary
shoe and install retaining clip.
(5) Install primary shoe on support plate. Secure
shoe with new spring retainers and pin.
(6) Install spring on parking brake strut and
engage strut in primary.
(7) Install secondary shoe on support plate (Fig.
51). Insert strut in shoe and guide shoe onto anchor
pin. Temporarily secure shoe with retaining pin.
(8) Install anchor plate and adjuster cable eyelet
on support plate anchor pin.
(9) Install cable guide in secondary shoe and posi-
tion cable in guide.
(10) Assemble adjuster screw (Fig. 52). Then
install and adjuster screw between the brake shoes.
CAUTION: Be sure the adjuster screws are installed
on the correct brake unit. The adjuster screws are
marked L (left) and R (right) for identification.
(11) Install adjuster lever and spring and connect
adjuster cable to lever.
(12) Install secondary shoe retainers and spring.
(13) Install shoe to shoe spring to secondary shoe,
then to primary shoe.(14)
Verify adjuster operation. Pull adjuster cable
upward, cable should lift lever and rotate star wheel. Be
sure adjuster lever properly engages star wheel teeth.
(15) Install the parking brake cable into guide
spring and insert cable into the backing plate.
(16) Adjust brake shoes to drum with brake gauge.
(17) Install wheel and tire assembly, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(18) Remove support and lower the vehicle.
INSTALLATION - 12 1/8 INCH
NOTE: Pivot screw and adjusting nut have left hand
threads on left side brake and right hand threads
on right side brake. Verify that adjusting nuts are
installed on correct side of vehicle.
(1) Coat contact pads on support plate with Mopar
high temperature grease, multi-mileage grease, or
equivalent.
(2) Assemble adjuster, lower spring and both brake
shoes. Then position the assembled components on
the support plate.
NOTE: Primary shoe is installed toward the front of
the vehicle and secondary toward the rear of the
vehicle.
(3) Install brake shoe hold-down springs and pins.
Be sure hold-down pins are seated in support plate
and springs are connected (Fig. 53).
(4) Insert parking brake cable through parking
brake cable guide spring to parking brake lever. Be
sure cable end is properly secured in lever.
(5) Install upper spring.
Fig. 51 Brake Shoe Installation
1 - SHOE RETURN SPRING
2 - ANCHOR PLATE
3 - ADJUSTER CABLE
4 - SHOE RETAINING PIN
5 - SECONDARY SHOE AND LINING
6 - PRIMARY SHOE AND LINING
7 - STRUT AND SPRING
Fig. 52 Adjuster Screw
1 - WASHER
2 - SOCKET
3 - STAMPED LETTER
L-LEFT BRAKE
R-RIGHT BRAKE
4 - SCREW THREADS
5 - NUT
6 - BUTTON
5 - 28 BRAKESBR/BE
BRAKE PADS/SHOES (Continued)

(6) Position adjuster lever return spring on pivot.
(7) Install adjuster lever.
(8) Attach adjuster cable to adjuster lever. Be sure
cable is properly routed.
(9) Adjust brake shoes to drum with brake gauge.
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. 54).
(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.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 55).
Fig. 53 Hold-Down Spring And Pin Attachment
1 - SHOE HOLD DOWN SPRING
2 - HOLD DOWN PIN
3 - BACKING PLATE
4 - BRAKE SHOE WEB
BR/BEBRAKES 5 - 29
BRAKE PADS/SHOES (Continued)