DODGE RAM 2002 Service Repair Manual

REMOVAL - FRONT ± 2500
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the caliper from the steering knuckle,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) and remove
caliper adapter assembly (Fig. 34).
NOTE: Do not allow brake hose to support caliper
adapter assembly.
(4) Remove the rotor from the hub/bearing wheel
studs.
REMOVAL - FRONT - 3500
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped.
(4) Remove the brake caliper adapter assembly.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL).
(5) Remove the rotor assembly.
INSTALLATION
INSTALLATION - REAR
(1) Install the hub to the rotor. Tighten the bolts to
128 N´m (95 ft. lbs.) (Fig. 35).
(2) Install the hub and rotor assembly.
(3) Install the rear axle shaft to the housing with
dual wheels, (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/REAR AXLE - 286RBI/AXLE SHAFTS -
INSTALLATION).
(4) Install the caliper adapter bolts.
(5) Install the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION). (Fig. 36).
(6) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.
Fig. 34 Caliper Adapter Assembly
1 - KNUCKLE
2 - CALIPER
3 - ROTOR
Fig. 35 ROTOR TO HUB
1 - Hub Bolts
2 - Socket
Fig. 36 ROTOR INSTALLED
5 - 22 BRAKES - BASEBR/BE
ROTORS (Continued)

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)

(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. 48).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 49).(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return under
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Pump the brake pedal several times to deplete
booster vacuum reserve.
(2) Remove brake lines from the master cylinder
(Fig. 50) .
(3) Remove mounting nuts from the master cylin-
der (Fig. 50) .
(4) Remove the master cylinder.
Fig. 47 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 48 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 49 Master Cylinder Bleeding±Typical
1 - BLEEDING TUBES
2 - RESERVOIR
BR/BEBRAKES - BASE 5 - 27
MASTER CYLINDER (Continued)

INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Install master cylinder on the booster mount-
ing studs.
(2) Install mounting nuts and tighten to 23 N´m
(17 ft. lbs.).
(3) Install brake lines and tighten to 19-23 N´m
(170-200 in. lbs.).
(4) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE)
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. 51).
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.
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 cable end connector (Fig. 52)
from the arm on the pedal assembly.
Fig. 50 Master Cylinder
1 - MOUNTING NUT
2 - MOUNTING NUT
3 - BRAKE LINES
4 - MASTER CYLINDER
Fig. 51 SHOES REMOVAL
1 - PARK BRAKE SHOES
2 - ADJUSTER
3 - RETURN SPRINGS
4 - SPLASH SHIELD
5 - HOLD DOWNS
5 - 28 BRAKES - BASEBR/BE
MASTER CYLINDER (Continued)

(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.).
(3) Connect the front cable to the arm on the pedal
assembly.
(4) Tighten the front cable grommet to the floor-
pan and the cable retainer, roll the carpet back.
(5) Connect the wires to the brake lamp switch.
(6) Install the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(7) Raise the vehicle.
(8) Adjust the parking brake cable tensioner.
CABLES
REMOVAL
REMOVAL - REAR PARK BRAKE CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 53).
(3) Loosen cable adjuster nut.
(4) Remove the rear park brake cable from the
intermediate park brake cable.(5) Compress tabs on cable end fitting on the rear
park brake cable to the frame mount bracket. Then
pull the cable through the bracket.
(6) Disengage the park brake cable from behind
the rotor assembly. (Fig. 54).
(7) Compress cable tabs on each cable end fitting
at the brake cable support plate.
(8) Remove the cables from the brake cable sup-
port plates.REMOVAL - FRONT PARKING BRAKE CABLE
(1) Raise and support vehicle.
(2) Loosen adjusting nut to create slack in front
cable.
Fig. 52 Parking Brake Pedal Assembly
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
Fig. 53 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 54 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
BR/BEBRAKES - BASE 5 - 29
PEDAL (Continued)

(3) Remove the front cable from the cable connec-
tor.
(4) Compress cable end fitting at underbody
bracket and remove the cable from the bracket.
(5) Lower vehicle.
(6) Push ball end of cable out of pedal clevis with
small screwdriver.
(7) Compress cable end fitting at the pedal bracket
and remove the cable (Fig. 55).
(8) Remove the left cowl trim and sill plate.
(9) Pull up the carpet and remove the cable from
the body clip.
(10) Pull up on the cable and remove the cable
with the body grommet.
INSTALLATION
INSTALLATION - REAR PARK BRAKE CABLE
(1) Push each cable end through the brake cable
support plate hole until the cable end fitting tabs
lock into place.
NOTE: Pull on the cable to ensure it is locked into
place.
(2) Push the cable through the frame bracket.
(3) Lock the left cable end fitting tabs into the
frame bracket hole.
(4) Install the rear cables into the tensioner rod
behind the rear of the brake assembly.(5) Install the cable to the intermediate cable con-
nector.
(6) Release and remove the lock out device.
(7) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(8) Remove the supports and lower the vehicle.
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) From inside the vehicle, insert the cable end
fitting into the hole in the pedal assembly.
(2) Seat the cable retainer in the pedal assembly.
(3) Engage the cable ball end in clevis on the pedal
assembly.
(4) Route the cable along the top of the wheel well
and clip in place.
(5) Route the cable through the floorpan and
install the body grommet.
(6) Place the carpet down and install the left cowl
trim and sill plate.
(7) Raise and support the vehicle.
(8) Route the cable through the underbody bracket
and seat the cable housing retainer in the bracket.
(9) Connect the cable to the cable connector.
(10) Perform the park brake adjustment proce-
dure, (Refer to 5 - BRAKES/PARKING BRAKE/CA-
BLE TENSIONER - ADJUSTMENTS).
(11) Lower the vehicle.
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 drum in hat assembly.
(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.
Fig. 55 Parking Brake Pedal
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
5 - 30 BRAKES - BASEBR/BE
CABLES (Continued)

(7) Install the drum in hat assembly and verify
that the rotor rotates 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. 56).
(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.
RELEASE HANDLE
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the driver side outboard end of
the instrument panel to access and unsnap the plas-tic retainer clip that secures the park brake release
linkage rod to the park brake mechanism on the left
cowl side inner panel.
(3) Disengage the park brake release linkage rod
end from the park brake mechanism.
(4) Lift the park brake release handle to access
and unsnap the plastic retainer clip that secures the
park brake release linkage rod to the lever on the
back of the park brake release handle.
(5) Lower the park brake release handle and reach
under the driver side outboard end of the instrument
panel to disengage the park brake release linkage
rod end from the lever on the back of the park brake
release handle.
(6) Lift the park brake release handle to access the
handle mounting bracket.
(7) Using a trim stick or another suitable wide
flat-bladed tool, gently pry each of the park brake
release handle mounting bracket latch tabs away
from the retaining notches in the instrument panel
receptacle (Fig. 57) .
(8) With both of the park brake release handle
mounting bracket latches released, slide the handle
and bracket assembly down and out of the instru-
ment panel receptacle.
Fig. 56 Adjustment Mark
1 - TENSIONER CABLE BRACKET
2 - TENSIONER
3 - CABLE CONNECTOR
4 - 6.35mm
(1/4 IN.)
5 - ADJUSTER NUTFig. 57 Park Brake Release Handle Remove/Install
1 - CLIP
2 - ROD
3 - MOUNTING BRACKET
4 - TRIM STICK
5 - LATCH TABS
6 - PARK BRAKE RELEASE HANDLE
BR/BEBRAKES - BASE 5 - 31
CABLE TENSIONER (Continued)