ECU DODGE RAM 2002 Service User Guide

Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to therequired thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6736 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 6).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
Fig. 6 PINION DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
3 - 52 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

(10) Insert Turning Bar C-6960-2 into the pinion
mate shaft hole in the case (Fig. 42).
(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in correct order during
removal (Fig. 43).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in correct order during
removal.
ASSEMBLY
Clean all components in cleaning solvent and dry
components with compressed air. Inspect clutch pack
plates for wear, scoring or damage. Replace both
clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
Inspect differential case and pinion shaft. Replace if
worn or damaged.
(1) Lubricate each component with gear lubricant
before assembly.
(2) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 44).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
Fig. 43 SIDE GEAR & CLUTCH PACK
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 44 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 42 PINION GEAR
1 - PINION GEARS
2 - TURNING BAR
3 - 70 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

Condition Possible Causes Correction
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid
type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion
depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued tot
he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position an axle lift under the axle and secure
it to the axle.
(3) Remove the wheels and tires.
(4) Remove RWAL sensor from the differential
housing, if necessary.
(5) Remove brake hose from the axle junction
block.
(6) Disconnect parking brake cables and cable
brackets.
(7) Remove vent hose from the axle shaft tube.(8) Mark propeller shaft and yoke for installation
alignment reference.
(9) Remove propeller shaft.
(10) Remove shock absorbers from the axle brack-
ets.
(11) Remove spring clamps and spring brackets.
(12) Remove axle from the vehicle.
INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.
(2) Install spring clamps and spring brackets.
3 - 82 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim/oil baffle equal to the dial indica-
tor reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 4). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Differential side bearing preload and gear backlash is
achieved by selective shims positioned behind the differ-
ential side bearing cones. The proper shim thickness
can be determined using slip-fit Dummy Bearings D-343
in place of the differential side bearings and a Dial Indi-
cator C-3339. Before proceeding with the differential
bearing preload and gear backlash measurements, mea-
sure the pinion gear depth and prepare the pinion for
installation. Establishing proper pinion gear depth is
essential to establishing gear backlash and tooth con-
tact patterns. After the overall shim thickness to take
up differential side play is measured, the pinion is
installed, and the gear backlash shim thickness is mea-
sured. The overall shim thickness is the total of the dial
indicator reading and the preload specification addedtogether. The gear backlash measurement determines
the thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the differ-
ential (Fig. 10). Differential shim measurements are
performed with spreader W-129-B removed.
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 267RBI 3 - 85
REAR AXLE - 267RBI (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Remove the RWAL sensor from the differential
housing, if necessary.
(6) Disconnect the brake hose at the axle junction
block.
(7) Disconnect the parking brake cables and cable
brackets.
(8)
Disconnect the vent hose from the axle shaft tube.
(9) Mark the propeller shaft and companion flange
for installation alignment reference.
(10) Remove propeller shaft.
(11) Disconnect shock absorbers from axle.
(12)
Remove the spring clamps and spring brackets.
(13) Separate the axle from the vehicle.
INSTALLATION
(1) Raise the axle with lifting device and align to
the leaf spring centering bolts.
(2) Install the spring clamps and spring brackets.
(3) Install the shock absorbers.
(4) Install the RWAL sensor to the differential
housing, if necessary
(5) Install the parking brake cables and cable
brackets.
(6)
Install the brake hose to the axle junction block.
(7) Install axle vent hose.
(8) Install the propeller shaft with reference marks
aligned.
(9) Install the wheels and tires.
(10) Add gear lubricant, if necessary. Refer to
Specifications for lubricant requirements.
(11) Remove lifting device from axle and lower the
vehicle.
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 147.625 mm (5.812 in.). The standard depth pro-
vides the best teeth contact pattern. Refer to Back-
lash and Contact Pattern Analysis Paragraph in this
section for additional information.
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 5).If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus amount needed.
Note the etched number on the face of the drive pin-
ion gear (±1, ±2, 0, +1, +2, etc.). The numbers represent
Fig. 4 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 SHIM LOCATIONS
1 - PINION BEARING PRELOAD SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - PINION GEAR DEPTH SHIM
3 - 112 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)

thousands of an inch deviation from the standard. If the
number is negative, add that value to the required
thickness of the depth shim(s). If the number is posi-tive, subtract that value from the thickness of the depth
shim(s). If the number is 0 no change is necessary. Refer
to the Pinion Gear Depth Variance Chart.
PINION GEAR DEPTH VARIANCE
Original
Pinion
Gear
Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set 6730 and Dial
Indicator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6738 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone 6740
hand tight (Fig. 6).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
Install differential bearing caps on Arbor Discs and
snug the bearing cap bolts. Then tighten cap bolts in
a criss-cross pattern to 108 N´m (80 ft. lbs.).
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
Fig. 6 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
BR/BEREAR AXLE - 286RBI 3 - 113
REAR AXLE - 286RBI (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube.
INSTALLATION
(1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube.
(2) Install the bolts and tighten to 129 N´m (95 ft.
lbs.).
AXLE BEARINGS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Remove the axle shaft.
(4) Remove the lock wedge and adjustment nut.
Remove adjustment nut with Socket DD-1241-JD.
(5) Remove the hub assembly. The outer axle bear-
ing will slide out as the hub is being removed.
(6) Drive grease seal and inner bearing out of the
hub with Installer 5064 and Handle C-4171.
(7) Remove bearing cups from the hub with a
brass drift and a hammer.
INSTALLATION
(1) Thoroughly clean both axle bearings and inte-
rior of the hub with an appropriate cleaning solvent.
(2) Install bearing cups with Installer 8153 and
Handle C-4171.
(3) Pack inner and outer bearings with Mopar
wheel bearing grease or equivalent
(4) Apply lubricant to surface area of the bearing
cup.
(5) Install inner axle bearing in the hub.
(6) Install anewbearing grease seal with
Installer 8152 and Handle C-4171.
(7) Inspect bearing and seal contact surfaces on
the axle tube spindle for burrs and/or roughness.
Remove all the rough contact surfaces from the axle
spindle.
CAUTION: Do not let grease seal contact the axle
tube threads during installation.
(8) Carefully slide the hub onto the axle.
(9) Install outer axle bearing.
(10) Install hub bearing adjustment nut with
Socket DD-1241±JD.
(11) Tighten adjustment nut to 163-190 N´m (120-
140 ft. lbs.) while rotating the wheel.(12) Loosen adjustment nut 1/8 of-a-turn to pro-
vide 0.001-inch to 0.010-inch wheel bearing end play.
(13) Tap the locking wedge into the spindle key-
way and adjustment nut.
NOTE: Locate locking wedge in a new position in
the adjustment nut.
(14) Install axle shaft and brake drum.
(15) Install wheel and tire assembly.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, pinion yoke, and pin-
ion shaft for installation reference.
(3) Disconnect the propeller shaft from the pinion
yoke. Secure the propeller shaft in an upright posi-
tion to prevent damage to the rear universal joint.
(4) Remove wheel and tire assemblies.
(5) Remove brake calipers to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate pinion yoke three or four times.
(7) Record the amount of torque necessary to
rotate the pinion gear with an inch pound dial-type
torque wrench.
(8) Hold the yoke with Holder 6719A and remove
the pinion shaft nut and washer.
(9) Remove yoke from the pinion with Remover
C-452 (Fig. 22).
(10) Remove pinion shaft seal with suitable pry
tool or slide-hammer mounted screw.
Fig. 22 Yoke Removal
1 - PINION YOKE
2 - REMOVER
BR/BEREAR AXLE - 286RBI 3 - 123

mile or two. However, if the lining is both soaked and
dirt contaminated, cleaning and/or replacement will
be necessary.
BRAKE LINING CONTAMINATION
Brake lining contamination is mostly a product of
leaking calipers or wheel cylinders, worn seals, driv-
ing through deep water puddles, or lining that has
become covered with grease and grit during repair.
Contaminated lining should be replaced to avoid fur-
ther brake problems.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
produce a grab-like condition as the tire loses and
recovers traction. Flat-spotted tires can cause vibra-
tion and generate shudder during brake operation. A
tire with internal damage such as a severe bruise,
cut, or ply separation can cause pull and vibration.
BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfaces
after a few brake applications causing the noise to
subside.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material
embedded in the brake lining will also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brake shoes in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors and drums can become so scored that replace-
ment is necessary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise. In addition, worn out,
improperly adjusted, or improperly assembled rear
brake shoes can also produce a thump noise.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
(1) Remove reservoir filler caps and fill reservoir.
(2) If calipers, or wheel cylinders were overhauled,
open all caliper and wheel cylinder bleed screws.
Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more
before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
(4)
Open up bleeder, then have a helper press down
the brake pedal. Once the pedal is down close the
bleeder. Repeat bleeding until fluid stream is clear and
free of bubbles. Then move to the next wheel.
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
BR/BEBRAKES - BASE 5 - 7
HYDRAULIC/MECHANICAL (Continued)

(3) Connect the pressure differential switch wire
connector.
(4) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
DISC BRAKE CALIPERS
DESCRIPTION
The caliper is a one-piece casting. The piston bores
are located in the inboard side. A square-cut piston
seal is located in a machined groove in the cylinder
bore.
The caliper pistons dust boot prevents dirt, water
and road splash from entering the piston bore. The
boot is seated in a groove machined at the outer end
of the caliper piston. The boot retaining flange is
seated in a counterbore machined in the outer end of
the caliper piston bore.
Ventilated disc brake rotors are used for all appli-
cations. The rotors are serviceable and can be
machined to restore surface finish when necessary.
OPERATION
When the brakes are applied fluid pressure is
exerted against the caliper piston. The fluid pressure
is exerted equally and in all directions. This means
pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 5).
Fluid pressure applied to the piston is transmitted
directly to the inboard brake shoe. This forces the
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within
the piston bore forces the caliper to slide inward on
the mounting bolts. This action brings the outboard
brake shoe lining into contact with the outer surface
of the disc brake rotor.
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will attempt to stop the rotors from turning and
bring the vehicle to a stop.
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake shoes do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seal controls the amount of pis-
ton extension needed to compensate for normal lining
wear.During brake application, the seal is deflected out-
ward by fluid pressure and piston movement (Fig. 6).
When the brakes (and fluid pressure) are released,
the seal relaxes and retracts the piston.
The amount of piston retraction is determined by
the amount of seal deflection. Generally the amount
is just enough to maintain contact between the pis-
ton and inboard brake shoe.
REMOVAL
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Compress the disc brake caliper using tool
#C4212F.
(4) Remove the caliper pin bolts.
(5) Remove the banjo bolt and discard the copper
washer.
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose with result. Provide a suitable support to hang
the caliper securely.
(6) Remove the rear disc brake caliper (Fig. 7).
Fig. 5 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
5 - 10 BRAKES - BASEBR/BE
COMBINATION VALVE (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