Brake Pedal - Rattle While Driving

NO: 05-08-96

GROUP: Brakes

DATE: Sept. 13, 1996

SUBJECT:
Brake Pedal Rattle

MODELS:
1994 - 1996 (BR) Ram Truck

SYMPTOM/CONDITION:

Customers may complain of a rattle coming from the brake pedal area while driving.

DIAGNOSIS:

Drive the vehicle on a rough surfaced road. If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied to the side of the brake pedal, perform the following Repair Procedure.

PARTS REQUIRED:

1 52009582 Wave Washer, Brake Pedal

REPAIR PROCEDURE:

This bulletin involves removing the brake pedal and installing a wave washer between the brake pedal and the brake pedal bushing.

1. Remove stop lamp fuse (fuse # 20)

2. Remove the knee bolster.

3. Remove stop lamp switch from mounting bracket, turning counter-clockwise.

4. Remove clip and washer attaching booster push rod and slide push rod off pedal.

5. Push shaft toward driver side of bracket just enough to expose left side E-clip then, remove E-clip with a flat blade screwdriver.

6. Push pedal shaft out of passenger side of bracket.

7. Remove brake pedal and pedal shaft from vehicle.





8. Remove bushing from passenger side of pedal (Figure 1).

9. Lubricate shaft bores in bracket and pedal with Mopar Multi-mileage Lube (P/N 4318063).

10. Install wave washer (P/N 52009582) onto bushing, then install bushing back into pedal.

NOTE:
THE BRAKE PEDAL SHOULD HAVE TWO BUSHINGS (ONE ON EACH END OF THE SHAFT BORE). REPLACE ALL DAMAGED OR MISSING BUSHINGS WITH BUSHING P/N 4294639.

11. Apply liberal quantity of Mopar Multi-mileage Lube to pedal shaft and to pedal bushings.

12. Position brake pedal in mounting bracket.

13. From passenger side, slide pedal shaft into bracket and through pedal.

14. Push pedal shaft out driver side of mounting bracket just enough to allow installation of retaining E-clip.

15. Install booster push rod on brake pedal. Secure push rod to pedal with washer and retaining clip.

16. Install stop lamp switch.

17. Install knee bolster.

18. Install stop lamp fuse.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 05-50-01-92 0.5 Hrs.

FAILURE CODE: XX - Service Adjustment