DODGE RAM 2003 Service Repair Manual

(10) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(11) Reconnect the negative battery cable.
ADJUSTABLE PEDAL MOTOR
DESCRIPTION
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
tions also allows the driver to set steering wheel tilt
and seat position to the most comfortable position.
The position of the brake and accelerator pedals can
be adjusted without compromising safety or comfort
in actuating the pedals.
Change of pedal position is accomplished by means
of a motor driven screw. Operating the adjustable
pedal switch activates the pedal drive motor (Fig.
45). The pedal drive motor turns a screw that
changes the position of the brake and accelerator
pedals. The pedal can be moved rearward (closer to
the driver) or forward (away from driver). The brake
pedal is moved on its drive screw to a position where
the driver feels most comfortable.
The accelerator pedal is moved at the same time
and the same distance as the brake pedal.
Neither the pedal drive motor (Fig. 45) nor drive
mechanism are subject to the mechanical stress of
brake or accelerator application.
²SYSTEM FEATURES:
²Range of Adjustment: The pedals may be
adjusted up to 3 in. (75 mm)
²Pedal Adjustment Speed: 0.5 in./sec (12.5
mm/sec)
²Pedal Adjustment Inhibitors: Pedal adjust-
ment is inhibited when the vehicle is in reverse or
when cruise control is activated.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the kneeblocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(3) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(4) Disconnect the adjustable pedal cables from the
brake and accelerator pedals.
(5) Disconnect the electrical connector.
(6) Unclip the cable fasteners to the support.(7) Remove the one mounting bolt for the adjust-
able pedal motor (Fig. 46).
(8) Remove the adjustable pedal motor with the
cables.
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
INSTALLATION
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
(1) Install the adjustable pedal motor with the
cables.
Fig. 45 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - CABLES
3 - ELECTRICAL CONNECTOR
Fig. 46 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - MOUNTING BOLT
5 - 24 BRAKES - BASEDR
PEDAL (Continued)

(2) Install the one mounting bolt for the adjustable
pedal motor (Fig. 46).
(3) Clip the cable fasteners to the support.
(4) Reconnect the electrical connector.
(5) Reconnect the adjustable pedal cables to the
brake and accelerator pedals.
(6) Install the new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the kneeblocker (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(8) Reconnect the negative battery cable.
(9) Check for proper operation of the pedals.
POWER BRAKE BOOSTER
DESCRIPTION
All models use a tandem diaphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster unit consists of a single housing
divided into two by a tandem diaphragm. The outer
edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Remove master cylinder. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/MASTER CYLINDER -
REMOVAL).
(2) Disconnect vacuum line at booster.
(3) Remove clip securing booster push rod to brake
pedal (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/PEDAL - REMOVAL). (Fig. 47).
(4) Remove the nuts from the booster mounting
studs (Fig. 47).
(5) Remove the booster and gasket from front cowl
panel.
INSTALLATION
(1) Guide the booster studs into the cowl panel
holes and seat the booster on the panel (Fig. 47).(2) Install and tighten new booster attaching nuts
to 28 N´m (250 in. lbs.).
(3) Install the booster push rod on brake pedal and
install clip (Fig. 47).
(4) Install the booster check valve if removed and
connect the vacuum hose to the check valve.
(5) Install the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION).
(6) Fill and bleed the brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
HYDRO-BOOST BRAKE
BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER
The hydraulic booster uses hydraulic pressure from
the power steering pump. Before diagnosing a
booster problem, first verify the power steering pump
is operating properly. Perform the following checks.
²Check the power steering fluid level.
²Check the brake fluid level.
²Check all power steering hoses and lines for
leaks and restrictions.
²Check power steering pump pressure.
NOISES
The hydraulic booster unit will produce certain
characteristic booster noises. The noises may occur
when the brake pedal is used in a manner not asso-
ciated with normal braking or driving habits.
Fig. 47 POWER BRAKE BOOSTER
1 - MOUNTING NUT
2 - POWER BRAKE BOOSTER
DRBRAKES - BASE 5 - 25
ADJUSTABLE PEDAL MOTOR (Continued)

HISSING
A hissing noise may be noticed when above normal
brake pedal pressure is applied, 40 lbs. or above. The
noise will be more noticeable if the vehicle is not
moving. The noise will increase with the brake pedal
pressure and an increase of system operating temper-
ature.
CLUNK-CHATTER-CLICKING
A clunk-chatter-clicking may be noticed when the
brake pedal is released quickly, after above normal
brake pedal pressure is applied 50-100 lbs..
BOOSTER FUNCTION TEST
With the engine off depress the brake pedal several
times to discharge the accumulator. Then depress the
brake pedal using 40 lbs. of force and start the
engine. The brake pedal should fall and then push
back against your foot. This indicates the booster is
operating properly.
ACCUMULATOR LEAKDOWN
(1) Start the engine, apply the brakes and turn the
steering wheel from lock to lock. This will ensure the
accumulator is charged. Turn off the engine and let
the vehicle sit for one hour. After one hour there
should be at least two power assisted brake applica-
tion with the engine off. If the system does not retain
a charge the booster must be replaced.
(2) With the engine off depress the brake pedal
several times to discharge the accumulator. Grasp
the accumulator and see if it wobbles or turns. If it
does the accumulator has lost a gas charge and the
booster must be replaced.
SEAL LEAKAGE
If the booster leaks from any of the seals the
booster assembly must be replaced (Fig. 48).²INPUT ROD SEAL:Fluid leakage from rear
end of the booster.
²PISTON SEAL:Fluid leakage from vent at
front of booster.
²HOUSING SEAL:Fluid leakage between hous-
ing and housing cover.
²SPOOL VALVE SEAL:Fluid leakage near
spool plug.
²RETURN PORT FITTING SEAL:Fluid leak-
age from port fitting.
HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Fig. 48 Hydraulic Booster Seals
1 - PUMP
2 - GEAR
3 - INPUT SEAL
4 - HOUSING SEAL
5 - ACCUMULATOR SEAL
6 - PISTON SEAL
7 - SPOOL PLUG SEAL
8 - RETURN
5 - 26 BRAKES - BASEDR
HYDRO-BOOST BRAKE BOOSTER (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 49).(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal.
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster.INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
Fig. 49 HYDRO-BOOST UNIT
1 - INLET HOSE
2 - HYDRO-BOOST UNIT
3 - MASTER CYLINDER UNIT
4 - RETURN HOSE
5 - OUTLET HOSE
DRBRAKES - BASE 5 - 27
HYDRO-BOOST BRAKE BOOSTER (Continued)

(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.
(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: MOPAR (MS-9602) ATF+4 is to be used in
the power steering system. No other power steering
or automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
(12) Bleed the hydraulic booster (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - STANDARD PROCEDURE).
ROTORS
REMOVAL
REMOVAL - REAR
(1) Raise and support the vehicle
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the caliper adapter bolts (Fig.
50).(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/DISC BRAKE CALIPER ADAPTER -
REMOVAL)
(5) Remove the retianing clips and rotor assembly
(Fig. 50).
REMOVAL - FRONT
(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. 51).
NOTE: Do not allow brake hose to support caliper
adapter assembly.(4) Remove the rotor from the hub/bearing wheel
studs (Fig. 52) or (Fig. 53).
INSTALLATION
INSTALLATION - REAR
(1) Install the rotor to the axleshaft (Fig. 50).
Fig. 50 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 51 Caliper Adapter Assembly
1 - KNUCKLE
2 - CALIPER
3 - ROTOR
5 - 28 BRAKES - BASEDR
HYDRO-BOOST BRAKE BOOSTER (Continued)

(2) Install the caliper adapter (Fig. 50) (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(3) Install the caliper adapter bolts (Fig. 50) and
tighten the mounting bolts to 135 N´m (100 ft.lbs).
(4) Install the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Lower the vehicle.
INSTALLATION - FRONT
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Install the rotor onto the hub/bearing wheel
studs.
(3) Install the caliper adapter assembly,(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION) and tighten
adapter bolts to:
(4) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE) and lower the vehicle.
(5) Apply the brakes several times to seat brake
pads. Be sure to obtain firm pedal before moving
vehicle.
SUPPORT PLATE
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(5) Remove the axle shaft (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(7) Remove the parking brake cable from the
brake lever.
(8) Remove the bolts attaching the support plate to
the axle and remove the support plate (Fig. 54).
INSTALLATION
(1) Install support plate on axle flange (Fig. 55).
Tighten attaching bolts to 115 N´m (85 ft. lbs.).
(2) Install parking brake cable in the brake lever.
(3) Install the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION). (Fig. 55).
(4) Install axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - INSTALLATION).
(5) Adjust brake shoes to drum with brake gauge
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS).
Fig. 52 FRONT ROTOR
1 - ROTOR
2 - HUB/BEARING
Fig. 53 8 LUG ROTOR ASSEMBLY
1 - SPRING
2 - SHOCK
3 - UPPER AND LOWER SUSPENSION ARMS
4 - DISC BRAKE CALIPER
5 - DISC BRAKE CALIPER ADAPTER
6 - ROTOR
DRBRAKES - BASE 5 - 29
ROTORS (Continued)

(6) Install the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION).
(7) Install the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(8) Install the caliper (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(9) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
PARKING BRAKE
DESCRIPTION
The parking brakes are operated by a system of
cables and levers attached to a primary and second-
ary shoe positioned within the drum section of the
rotor.
The drum-in-hat design utilizes an independent set
of shoes to park the vehicle (Fig. 56).
OPERATION
To apply the parking brake the pedal is depressed.
This creates tension in the cable which pulls forward
on the park brake lever. The lever pushes the park
brake shoes outward and into contact with the drum
section of the rotor. The contact of shoe to rotor parks
the vehicle.
A torsion locking mechanism is used to hold the
pedal in an applied position. Parking brake release is
accomplished by the hand release.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
ing light whenever the parking brake is applied.
Parking brake adjustment is controlled by a cable
tensioner mechanism. The cable tensioner, once
adjusted at the factory, should not need further
adjustment under normal circumstances. Adjustment
may be required if a new tensioner, or cables are
installed, or disconnected.
Fig. 54 SUPPORT PLATE
1 - SUPPORT PLATE
2 - MOUNTING STUDS
Fig. 55 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
Fig. 56 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
5 - 30 BRAKES - BASEDR
SUPPORT PLATE (Continued)

CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE CABLE
(1) Raise and support vehicle.
(2) Lockout the parking brake cable (Fig. 58).
(3) Loosen adjusting nut to create slack in front
cable.
(4) Remove the front cable from the cable connec-
tor.
(5) Compress cable end fitting at underbody
bracket and remove the cable from the bracket.
(6) Lower vehicle.
(7) Push ball end of cable out of pedal clevis with
small screwdriver.
(8) Compress cable end fitting at the pedal bracket
and remove the cable (Fig. 57).
(9) Remove the left cowl trim and sill plate.
(10) Pull up the carpet and remove the cable from
the body clip.
(11) Pull up on the cable and remove the cable
with the body grommet.
REMOVAL - REAR PARK BRAKE CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 58).
(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. 59).
(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 - RIGHT REAR CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 58).
(3) Loosen the brake cable at the equalizer and
adjuster nut.
(4) Remove the right cable from the front cable.
(5) Remove the right cable from the equalizer.
Fig. 57 Parking Brake Pedal
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
Fig. 58 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 59 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
DRBRAKES - BASE 5 - 31

(6) Remove the cable from the frame bracket.
(7) Remove the cable from the axle bracket.
(8) Remove the cable bracket from the shock
bracket.
(9) Remove the brake cable from the brake lever.
(Fig. 60)
REMOVAL - LEFT REAR CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 58).
(3) Loosen the brake cable at the equalizer and
adjuster nut.
(4) Remove the left brake cable from the equalizer.
(5) Remove the brake cable from the frame
bracket.
(6) Remove the brake cable from the brake lever.
(Fig. 61)
INSTALLATION
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 through the floorpan and
install the body grommet.
(5) Place the carpet down and install the left cowl
trim and sill plate.
(6) Raise and support the vehicle.
(7) Route the cable through the underbody bracket
and seat the cable end fitting in the bracket.(8) Connect the cable to the cable connector.
(9) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(10) Lower the vehicle.
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 - RIGHT REAR CABLE
(1) Install the brake cable to the brake lever. (Fig.
62)
(2) Install the cable bracket to the shock bracket.
(3) Install the cable to the axle bracket.
(4) Install the cable to the frame bracket.
(5) Install the right cable to the equalizer.
Fig. 60 CABLE MOUNT
1 - SUPPORT PLAT
2 - CABLE MOUNT
3 - PARK BRAKE LEVER
4 - CABLE
Fig. 61 REAR DISC BRAKE
1 - DISC BRAKE CALIPER
2 - DISC BRAKE ROTOR
3 - DUST SHIELD
4 - REAR PARKING BRAKE CABLE
5 - DISC BRAKE CALIPER MOUNTING BOLTS
5 - 32 BRAKES - BASEDR
CABLES (Continued)

(6) Install the right cable to the front cable.
(7) Adjust the brake cable at the equalizer and
using the adjuster nut.
INSTALLATION - LEFT REAR CABLE
(1) Install the brake cable to the brake lever (Fig.
61).
(2) Install the brake cable to the frame bracket.
(3) Install the left brake cable to the equalizer.
(4) Adjust the brake cable at the equalizer and
adjuster nut.
SHOES
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper,(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the disc brake rotor, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(5) Lockout the parking brake cable (Fig. 63).
(6) Disengage the park brake cable from behind
the rotor assembly to allow easier disassembly of the
park brake shoes (Fig. 64).
(7) Remove the axleshaft (Fig. 65) (Refer to 3 -
DIFFERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/
AXLE SHAFTS - REMOVAL).
(8) Disassemble the rear park brake shoes (Fig.
56).
CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including
the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.
INSPECTION - REAR DRUM IN HAT BRAKE
As a general rule, riveted brake shoes should be
replaced when worn to within 0.78 mm (1/32 in.) of
the rivet heads. Bonded lining should be replaced
when worn to a thickness of 1.6 mm (1/16 in.).
Examine the lining contact pattern to determine if
the shoes are bent or the drum is tapered. The lining
should exhibit contact across its entire width. Shoes
exhibiting contact only on one side should be
Fig. 62 PARKING BRAKE CABLE
1 - SUPPORT PLAT
2 - CABLE
3 - LEVER
Fig. 63 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 64 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
DRBRAKES - BASE 5 - 33
CABLES (Continued)