boot DODGE RAM 2002 Service Repair Manual

SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Center Bearing Bolts 68 50 -
Front Shaft Flange Yoke 88 65 -
Front Shaft Axle Yoke 19 14 -
Rear Shaft Axle Yoke 29 22 -
SPECIAL TOOLS
PROPELLER SHAFT
PROPELLER SHAFT - FRONT
REMOVAL
(1) Shift the transmission and transfer case to
their neutral positions.(2) Raise and support vehicle and remove skid
plate, if equipped.
(3) Mark a line across the companion flange at the
transfer case and propeller shaft flange yoke for
installation reference.
(4) Mark a line across the propeller shaft yoke and
the pinion shaft yoke for installation reference.
(5) Remove the universal joint strap bolts at the
pinion shaft yoke (Fig. 9).
(6) Remove the bolts holding the propeller shaft to
the transfer case companion flange.
(7) Remove the propeller shaft.
Inclinometer - 7663
Bearing Splitter - 1130
Installer, Bearing - 6052Fig. 9 Front Propeller Shaft
1 - TRANSFER CASE
2 - FRONT AXLE
3 - AXLE YOKE
4 - SLIP YOKE BOOT
5 - STRAP
6 - FLANGE YOKE/COMPANION FLANGE
3 - 6 PROPELLER SHAFTBR/BE
PROPELLER SHAFT (Continued)

CENTER BEARING
REMOVAL
(1) Remove rear propeller shaft.
(2) Remove slip joint boot clamp and separate the
two half-shafts.
(3) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(4) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during
removal of center bearing.
(5)
Set shaft in press and press bearing off the shaft.
INSTALLATION
NOTE: Two types of center bearings are used and
are not interchangeable. Install the same type as
the vehicle was built with.
(1) Install new slinger on shaft and drive into posi-
tion with appropriate installer tool.
(2) Install new center bearing on shaft with Bear-
ing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multi-
purpose grease.
(4) Align master splines and slide front and rear
half-shafts together. Reposition slip yoke boot and
install new clamp.
(5) Install propeller shaft in vehicle.
ADJUSTMENTS
ADJUSTMENT - CENTER BEARING
Launch shudder is a vibration that occurs at first
acceleration from a stop. Shudder vibration usually
peaks at the engines highest torque output. Shudder is
a symptom associated with vehicles using a two-piece
propeller shaft. To decrease shudder, lower the center
bearing in 1/8 inch increments. Use shim stock or fab-
ricated plates. Plate stock must be used to maintain
compression of the rubber insulator around the bearing.
Do not use washers. Replace the original bolts with the
appropriate increased length bolts.
SINGLE CARDAN UNIVERSAL
JOINTS
DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) With a soft drift, tap the outside of the bearing
cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 12).
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 13).
Fig. 12 Remove Snap Ring
1 - SNAP RING
3 - 8 PROPELLER SHAFTBR/BE

SPECIAL TOOLS
BASE BRAKESHYDRAULIC/MECHANICAL
DESCRIPTION
This vehicle is equipped with front disc brakes and
rear drum brakes also certain vehicles have four
wheel disc brakes. The front and rear disc brakes
consist of dual piston calipers and ventilated rotors.
The rear brakes are dual brake shoe, internal
expanding units with cast brake drums. The parking
brake mechanism is cable operated and connected to
the rear brake trailing shoes. Power brake assist is
standard equipment. A vacuum operated power brake
booster is used on gas engine vehicles. A hydraulic
booster is used on diesel engine vehicles.
Two antilock brake systems are used on this vehi-
cle. A rear wheel antilock (RWAL) brake system and
all-wheel antilock brake system (ABS). The RWAL
and ABS systems are designed to retard wheel
lockup while braking. Retarding wheel lockup is
accomplished by modulating fluid pressure to the
wheel brake units. Both systems are monitored by a
microprocessor which controls the operation of the
systems.
WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET LININGS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
Installer, Brake Caliper Dust Boot C-4340
Installer, Brake Caliper Dust Boot C-3716-A
Handle C-4171
Cap, Master Cylinder Pressure Bleed 6921
5 - 4 BRAKES - BASEBR/BE
BRAKES - BASE (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)

REMOVAL - FRONT
(1) Raise and support vehicle.
(2) Remove front wheel and tire assembly.
(3) Remove caliper brake hose bolt, washers and
hose (Fig. 8).
(4) Remove caliper mounting bolts.
(5) Tilt the top of the caliper up and remove it
from the adapter.
(6) Remove anti-rattle springs.
NOTE: Upper and lower anti-rattle springs are not
interchangeable.
DISASSEMBLY
(1) Drain the brake fluid from caliper.
(2) C-clamp a block of wood over one piston (Fig.
9).
(3) Take another piece of wood and pad it with
one-inch thickness of shop towels. Place this piece in
the outboard shoe side of the caliper in front of the
other piston. This will cushion and protect caliper
piston during removal (Fig. 10).
(4) To remove the caliper piston directshort
bursts of low pressure airwith a blow gun
through the caliper brake hose port. Use only enough
air pressure to ease the piston out.
Fig. 6 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
Fig. 7 REAR CALIPER
1 - Banjo Bolt
2 - Caliper Pin Bolts
Fig. 8 Caliper
1 - WASHERS
2 - MOUNTING BOLTS
3 - HOSE BOLT
Fig. 9 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
BR/BEBRAKES - BASE 5 - 11
DISC BRAKE CALIPERS (Continued)

CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.
(5) Remove the C-clamp and block of wood from
the caliper and clamp it over the dust boot of the
first piston removed. This will seal the empty piston
bore.
(6) Move the padded piece of wood in front of the
other piston.
(7) Remove the second piston using the same pro-
cedure withshort bursts of low pressure air.
(8) Remove piston dust boots with a suitable pry
tool (Fig. 11).
(9) Remove piston seals from caliper (Fig. 12).
CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Push caliper mounting bolt bushings out of
the boot seals and remove the boot seals from the
caliper (Fig. 13).
(11) Remove caliper bleed screw.
CLEANING
Clean the caliper components with clean brake
fluid or brake clean only. Wipe the caliper and piston
dry with lint free towels or use low pressure com-
pressed air.CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
The piston must be replaced if cracked or scored.
Do not attempt to restore a scored piston surface by
sanding or polishing.
Fig. 10 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 11 Piston Dust Boot Removal
1 - CALIPER
2 - DUST BOOT
Fig. 12 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
5 - 12 BRAKES - BASEBR/BE
DISC BRAKE CALIPERS (Continued)

CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can belightlypolished with a brake
hone to remove very minor surface imperfections
(Fig. 14). The caliper should be replaced if the bore is
severely corroded, rusted, scored, or if polishing
would increase bore diameter more than 0.025 mm
(0.001 inch).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubricate caliper pistons, piston seals and pis-
ton bores with clean, fresh brake fluid.
(2) Install new piston seals into caliper bores (Fig.
15).
NOTE: Verify seal is fully seated and not twisted.
(3) Lightly lubricate lip of new boot with silicone
grease. Install boot on piston and work boot lip into
the groove at the top of piston.
(4) Stretch boot rearward to straighten boot folds,
then move boot forward until folds snap into place.
(5) Install piston into caliper bore and press piston
down to the bottom of the caliper bore by hand or
with hammer handle (Fig. 16).
(6) Seat dust boot in caliper (Fig. 17) with Handle
C-4171 and Installer:
²HD 56 mm caliper: Installer C-4340
²LD 54 mm caliper: Installer C-3716-A
(7) Install the second piston and dust boot.
(8) Lubricate caliper mounting bolt bushings, boot
seals and bores with Mopar brake grease or Dow
Corningt807 grease only.
CAUTION: Use of alternative grease may cause
damage to the boots seals.
(9) Install the boot seals into the caliper seal bores
and center the seals in the bores.
Fig. 13 Bushings And Boot Seals
1 - CALIPER
2 - BUSHING
3 - BOOT SEAL
Fig. 14 Polishing Piston Bore
1 - HONE
2 - CALIPER
3 - PISTON BORE
Fig. 15 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
BR/BEBRAKES - BASE 5 - 13
DISC BRAKE CALIPERS (Continued)

(10) Install mounting bolt bushings into the boot
seals and insure seal lip is engaged into the bushing
grooves at either end of the bushing.
(11) Install caliper bleed screw.
INSTALLATION
INSTALLATION - REAR
NOTE: Install a new copper washers on the banjo
bolt when installing
(1) Install the rear disc brake caliper (Fig. 18).(2) Install the banjo bolt with new copper washers
to the caliper.tighten to 38 N´m (28 ft. lbs.)
(3) Install the caliper pin bolts. tighten to 33 N´m
(25 ft. lbs.)
(4) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(5) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(6) Lower the vehicle.
INSTALLATION - FRONT
(1) Clean the caliper mounting adapter and the
anti-rattle springs and grease with Mopar brake
grease or Dow Corningt807 grease only.
(2) Install the anti-rattle springs.
(3) Tilt the bottom of the caliper over the rotor and
under the adapter. Then push the top of the caliper
down onto the adapter.
(4) Install the caliper mounting bolts and tighten
to 33 N´m (24 ft. lbs.).
(5) Install the brake hose to caliper withnew seal
washersand tighten fitting bolt to 24 N´m (18 ft.
lbs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(6) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(7) Install the wheel and tire assemblies, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
Fig. 16 Caliper Piston Installation
1 - CALIPER
2 - DUST BOOT
3 - PISTON
Fig. 17 Seating Dust Boot
1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER
Fig. 18 REAR CALIPER INSTALL
1 - ROTOR
2 - BRAKE SHOES
3 - DISC BRAKE CALIPER
5 - 14 BRAKES - BASEBR/BE
DISC BRAKE CALIPERS (Continued)

(3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Lubricate release fork and pivot contact sur-
faces with Mopar High Temperature wheel bearing
grease or equivalent before installation.
(5) Align and install clutch housing on transmis-
sion (Fig. 19). Tighten housing bolts closest to align-
ment dowels first and to the following torque values:
²1/4in. diameter ªAº bolts - 4.5 N´m (40 in.lb.).
²3/8in. diameter ªAº bolts - 47.5 N´m (35 ft.lb.).
²7/16in. diameter ªAº bolts - 68 N´m (50 ft.lb.).
²ªBº bolts for 5.2L/5.9L applications - 41 N´m (30
ft.lb.).
²ªBº bolts for 5.9L TD/8.0L applications - 47.5
N´m (35 ft.lb.).
²ªCº bolts for 5.2/5.9L applications - 68 N´m (50
ft.lb.).
²ªCº bolts for 5.9L TD applications - 47.5 N´m (35
ft.lb.).
²ªCº bolts for 8.0L applications - 74.5 N´m (55
ft.lb.).
(6) Install transmission-to-engine strut after
installing clutch housing. Tighten bolt attaching
strut to clutch housing first and engine bolt last.
(7) Install the starter to the clutch housing.
(8) Install the clutch housing dust shield to the
clutch housing. Tighten the bolts to
(9) Install transmission and transfer case, if
equipped. Refer to 21Transmission and Transfer Case
for proper procedures.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case forprocedures.
(2) Remove clutch housing, for NV4500 equipped
vehicles.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 20).
INSTALLATION
NOTE: Inspect bearing slide surface on transmis-
sion front bearing retainer. Replace retainer if slide
surface is scored, worn or cracked. Inspect release
lever and pivot stud. Be sure stud is secure and in
good condition. Be sure fork is not distorted or
worn. Replace fork spring clips if bent or damaged.
(1) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud and release lever
pivot surface with Mopar high temperature bearing
grease or equilvalent.
Fig. 18 Transmission/Clutch Housing - NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
Fig. 19 Clutch Housing Installation - NV4500
1 - ENGINE BLOCK
2 - CLUTCH DISC AND COVER
3 - CLUTCH HOUSING
4 - DUST COVER
6 - 12 CLUTCHBR/BE
CLUTCH HOUSING (Continued)

to solenoid battery terminal stud. Do not let starter
motor hang from wire harness.
(8) Remove battery positive cable wire harness
connector eyelet from solenoid battery terminal stud.
(9) Disconnect battery positive cable wire harness
connector from solenoid terminal connector recepta-
cle.
(10) Remove starter motor.
5.9L DIESEL ENGINE
(1) Disconnect and isolate negative cables of both
batteries.
(2) Raise and support vehicle.
(3) Pull back protective rubber boot from solenoid
battery terminal far enough to access and remove
nut securing battery positive cable wire harness con-
nector eyelet to solenoid battery terminal stud (Fig.
10).
(4) Remove nut securing battery positive cable
wire harness solenoid connector eyelet to solenoid
terminal stud.
(5) Remove battery positive cable wire harness
connector eyelets from solenoid terminal studs.(6) While supporting starter motor, remove three
bolts securing starter motor to flywheel housing (Fig.
10) and (Fig. 11).
(7) Remove starter motor from engine (certain die-
sel engines have an aluminum spacer mounted
between the starter and the starter mounting flange.
Note position and orientation of spacer before remov-
al).
8.0L GASOLINE ENGINE
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove nut securing battery positive cable
wire harness connector eyelet to solenoid battery ter-
minal stud (Fig. 12).
(4) Remove battery positive cable connector eyelet
from solenoid battery terminal stud.
(5) Disconnect battery positive cable wire harness
connector from solenoid terminal connector recepta-
cle.
Fig. 9 Starter Motor Remove/Install - 5.9L Gasoline
Engine
1 - ENGINE
2 - STARTER MOUNTING FLANGE
3 - STUD
4 - STARTER MOTOR
5 - LOCK WASHER
6 - NUT
7 - BRACKET
8 - BOLT
9 - POSITIVE BATTERY CABLE WIRE HARNESS
10 - POSITIVE BATTERY CABLE WIRE HARNESS NUT
Fig. 10 Starter Motor Wire Harness Remove/Install -
5.9L Diesel Engine
1 - SOLENOID WIRE
2 - MOUNTING BOLTS (3)
3 - BATTERY TERMINAL
BR/BESTARTING 8F - 39
STARTER MOTOR (Continued)