Dodge Ram Truck 1500-2500-3500. Manual — part 207
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 (3) and bushings (2). If the bushings (2)
become dry a spray lubricant can be used to eliminate
noises. The booster push rod is attached to the pedal
with a clip (1). The pedal (4), bushings (2), pivot pin
(3)
and
support
bracket
are
not
serviceable
components.
OPERATION
The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod
is depressed which moves the booster secondary rod. The booster secondary rod depress the master cylinder
piston.
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 (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
3. Remove the brake lamp switch and discard (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL).
4. On vehicles equipped with adjustable pedals.
Disconnect the adjuster cable (1) to the pedal (2).
5. Remove the steering column (Refer to 19 - STEERING/COLUMN - REMOVAL).
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BRAKES - BASE - SERVICE INFORMATION
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6. Remove the brake booster (5) (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/fas-
teners (4).
INSTALLATION
1. Install the pedal assembly (4) to the vehicle.
2. Install the mounting bolts (3) and tighten to 28 N·m
(21 ft. lbs.).
3. Reconnect the accelerator cable (1) to the pedal
(2).
4. Install the module mounting bolts and tighten to 38 N·m (28 ft. lbs.).
5. Reconnect the electrical connectors.
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BRAKES - BASE - SERVICE INFORMATION
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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.
10. Install the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
11. Reconnect the negative battery cable.
BOOSTER-POWER BRAKE
DESCRIPTION
All models use a tandem diaphragm, power brake
booster (3).
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 (3). The outer edge
of the diaphragm is secured to the housing. A spacer
block (2) is located in between the cowl and the
booster housing. The booster push rod (1), connects
the booster to the brake pedal and master cylinder (4),
is attached to the center of the diaphragm. A check
valve (5) is used in the booster outlet connected to the
engine intake manifold. Power assist is generated by
utilizing a combination of vacuum and atmospheric
pressure to boost brake assist.
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BRAKES - BASE - SERVICE INFORMATION
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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/ME-
CHANICAL/PEDAL - REMOVAL)..
4. Remove the nuts (1) from the booster mounting
studs.
5. Remove the booster (2) and gasket from front cowl
panel.
INSTALLATION
1. Guide the booster (2) studs into the cowl panel
holes and seat the booster on the panel.
2. Install and tighten new booster attaching nuts (1) to
28 N·m (250 in. lbs.).
3. Install the booster push rod on brake pedal and install clip.
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 - INSTAL-
LATION).
6. Fill and bleed the brake system. (Refer to 5 - BRAKES - STANDARD PROCEDURE).
BOOSTER-HYDRO-BOOST BRAKE
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.
•
Check the power steering fluid level.
•
Check the brake fluid level.
•
Check all power steering hoses and lines for leaks and restrictions.
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