brake DODGE RAM 2003 Service Manual PDF

FLUID RESERVOIR
REMOVAL
(1) Install the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the reservoir cap and siphon fluid into
a drain container (Fig. 34).
(3) Remove the electrical connector from the fluid
level switch in the reservoir (Fig. 34).
(4) Remove the reservoir mounting bolt (Fig. 34).
(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body (Fig.
34).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate the new grommets with clean brake
fluid and Install new grommets in cylinder body. Use
finger pressure to install and seat grommets.
(2) Start the reservoir in grommets. Then rock the
reservoir back and forth while pressing downward to
seat it into the grommets.
(3) Install the mounting bolt for the reservoir to
the master cylinder.
(4) Reconnect the electrical connector to the fluid
reservoir level switch.
(5) Remove the prop rod from the vehicle.(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE JUNCTION BLOCK
REMOVAL
(1) Remove the brake lines from the junction block
(Fig. 35).
(2) Remove the junction block mounting bolt and
remove the junction block from the bracket (Fig. 35).
INSTALLATION
(1) Position the junction block on the bracket and
install the mounting bolt. Tighten the mounting bolt
to 23 N´m (210 in. lbs.) (Fig. 35).
(2) Install the brake lines into the junction block
and tighten to 19-23 N´m (170-200 in. lbs.) (Fig. 35).
(3) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
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 and has a switch for indicat-
ing low fluid levels. The reservoir is the only service-
able component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
Fig. 34 FLUID RESERVOIR
1 - MASTER CYLINDER CAP
2 - FLUID RESERVOIR
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - MOUNTING BOLT
6 - GROMMETS
Fig. 35 JUNCTION BLOCK
1 - BRAKE LINES
2 - JUNCTION BLOCK
DRBRAKES - BASE 5 - 19

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. 36).(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. 37).
(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.
Fig. 36 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
5 - 20 BRAKES - BASEDR
MASTER CYLINDER (Continued)

(1) Mount master cylinder in vise.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 38).
(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
REMOVAL - ALL EXCEPT HYDROBOOST
(1) Remove the brake lines from the master cylin-
der (Fig. 39).
(2) Disconnect the electrical connector for the low
fluid level.
(3) Remove the mounting nuts from the master
cylinder (Fig. 39).
(4) Remove the master cylinder.NOTE: Using care remove the master cylinder
directly forward in order not to dislodge the output
rod from its seat inside the booster.
REMOVAL - HYDROBOOST
(1) Remove the brake lines from the master cylin-
der (Fig. 40).
(2) Disconnect the electrical connector for the low
fluid level.
(3) Remove the mounting nuts from the master
cylinder (Fig. 40).
(4) Remove the master cylinder.
Fig. 37 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 38 Master Cylinder Bleeding±Typical
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 39 MASTER CYLINDER
1 - MASTER CYLINDER RESERVOIR
2 - POWER BRAKE BOOSTER
3 - BRAKE LINES
4 - MASTER CYLINDER
Fig. 40 HYDROBOOST MASTER CYLINDER
1 - HYDROBOOST UNIT
2 - MASTER CYLINDER RESERVOIR
3 - MASTER CYLINDER
4 - MOUNTING NUTS
DRBRAKES - BASE 5 - 21
MASTER CYLINDER (Continued)

NOTE: Using care remove the master cylinder
directly forward in order not to dislodge the output
rod from its seat inside the booster.
INSTALLATION
INSTALLATION - ALL EXCEPT HYDROBOOST
NOTE: If master cylinder is replaced bleed cylinder
before installation.
NOTE: Make sure the output rod of the brake
booster is in position before mounting of the mas-
ter cylinder ªThis position will enable the output
rod to enter inside of the master cylinder plunger
sleeve during installationº. Proper position is
obtained when the output rod is centered perpen-
dicular to the master cylinder mounting hole (Fig.
41).
NOTE: Before installing the master cylinder, pump
the brake pedal several times with the engine off to
remove vacuum from the booster.
(1) Install the master cylinder on the booster
mounting studs.
(2) Install new mounting nuts and tighten to 25
N´m (221 in. lbs.)
(3) Install the brake lines and tighten to 19 N´m
(170 in. lbs.)(4) Reconnect the elctrical connector for the low
fluid level switch.
(5) Fill and bleed the base brake system. (Refer to
5 - BRAKES - STANDARD PROCEDURE).
INSTALLATION - HYDROBOOST
NOTE: If master cylinder is replaced bleed cylinder
before installation.
NOTE: Make sure the output rod of the brake
booster is in position before mounting of the mas-
ter cylinder ªThis position will enable the output
rod to enter inside of the master cylinder plunger
sleeve during installationº. Proper position is
obtained when the output rod is centered perpen-
dicular to the master cylinder mounting hole (Fig.
41).
(1) Install the master cylinder on the booster
mounting studs (Fig. 40).
(2) Install new mounting nuts and tighten to 25
N´m (221 in. lbs.)
(3) Install the brake lines and tighten to 19 N´m
(170 in. lbs.)
(4) Reconnect the elctrical connector for the low
fluid level switch.
(5) Fill and bleed the base brake system. (Refer to
5 - BRAKES - STANDARD PROCEDURE).
PEDAL
DESCRIPTION
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
A suspended-type brake pedal is used. The pedal is
attached to the pedal support bracket with a pivot
shaft pin and bushings. If the bushings become dry a
spray lubricant can be used to eliminate noises. The
booster push rod is attached to the pedal with a clip.
The pedal, bushings, pivot pin and support bracket
are not serviceable components (Fig. 42).
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which move the booster
secondary rod. The booster secondary rod depress the
master cylinder piston.
Fig. 41 OUTPUT ROD ORIENTATION
1 - MASTER CYLINDER RESERVOIR
2 - CHECK VALVE
3 - BOOSTER
4 - BOOSTER MOUNTING STUDS
5 - INPUT ROD
6 - OUTPUT ROD
7 - MASTER CYLINDER MOUNTING STUDS
8 - MASTER CYLINDER
9- ELECTRICAL CONNECTOR
5 - 22 BRAKES - BASEDR
MASTER CYLINDER (Continued)

REMOVAL
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
(1) Disconnect the negative battery cable.
(2) Remove the steering column opening cover(Re-
fer to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - REMOVAL).
(3) Remove the brake lamp switch and discard(Re-
fer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTE-
RIOR/BRAKE LAMP SWITCH - REMOVAL).
(4)On vehicles equipped with adjustable ped-
als.Disconnect the adjuster cable to the pedal (Fig.
43).
(5) Remove the steering column (Refer to 19 -
STEERING/COLUMN - REMOVAL).
(6) Remove the brake booster (Fig. 44)(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - REMOVAL).
(7) Disconnect the electrical connectors.
(8) Remove the module mounting bolts.
(9) Disconnect the accelerator pedal cable.
(10) Remove the pedal assembly mounting nuts/
fasteners (Fig. 44).
INSTALLATION
(1) Install the pedal assembly to the vehicle (Fig.
44).
(2) Install the mounting bolts (Fig. 44) and tighten
to 28 N´m (21 ft. lbs.).
(3) Reconnect the accelerator cable to the pedal.(4) Install the module mounting bolts and tighten
to 38 N´m (28 ft. lbs.).
(5) Reconnect the electrical connectors.
(6) Install the brake booster (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/POWER BRAKE
BOOSTER - INSTALLATION).
(7) Install the steering column (Refer to 19 -
STEERING/COLUMN - INSTALLATION).
(8) Install a new brake lamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(9)On vehicles equipped with adjustable
brake pedal.Reconnect the electrical connector to
the motor and the adjuster cable at the pedal.
Fig. 42 BRAKE PEDAL
1 - CLIP
2 - BUSHINGS
3 - PIVOT SHAFT PIN
4 - PEDAL ASSEMBLY
ADJUSTABLE PEDAL SHOWN
NON ADJUSTABLE PEDAL IS SIMILIAR
5-PAD
Fig. 43 PEDAL/CABLE
1 - CABLE
2 - BRAKE PEDAL ASSEMBLY
Fig. 44 PEDAL ASSEMBLY (ADJUSTABLE PEDALS
SHOWN)
1 - ADJUSTABLE PEDAL MOTOR
2 - PEDAL ASSEMBLY BRACKET
3 - MOUNTING NUT
4 - BRAKE & ACCELERATOR PEDAL
5 - BRAKE BOOSTER MOUNTING STUDS
DRBRAKES - BASE 5 - 23
PEDAL (Continued)

(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)