3500 Series Vehicles Only - Rear Brake Shoe Replacement
NOTE:THIS PORTION OF THE REPAIR PROCEDURE APPLES TO 3500 SERIES RAM TRUCKS BUILT BEFORE AUG. 5, 1996 (MDH 0805XX).
1. Be sure parking brake is released.
2. Raise the vehicle on an appropriate lift.
3. Remove rear wheel and tire assemblies.
4. Remove brake drum.
5. Remove primary (front) brake shoe return spring from anchor pin with brake pliers (Figure 7).
6. Remove primary brake shoe hold-down spring, pin, and retainers using a hold-down spring tool.
7. Disconnect shoe spring and remove primary brake shoe and parking brake lever strut.
8. Remove adjuster screw assembly.
9. Remove secondary brake shoe hold-down spring, pin, and retainer assembly then, remove adjuster lever, spring, and spring retainer assembly. It is not necessary to disassemble adjuster lever components unless they are worn or damaged.
10. Disconnect parking brake cable from lever attached to secondary brake shoe then remove brake shoe.
11. Remove and discard E-clip attaching parking brake lever to secondary brake shoe and remove lever.
NOTE:
REAR WHEEL CYLINDER OR REAR AXLE SEAL SERVICE MUST BE PERFORMED PRIOR TO CONTINUING IF THERE IS ANY EVIDENCE OF LEAKAGE. REFER TO THE 1997 RAM TRUCK SERVICE MANUAL (PUBLICATION NO. 81-370-7108) PAGE 5-32 FOR INFORMATION REGARDING WHEEL CYLINDER SERVICE OR PAGES 3-87 THROUGH 3-152 FOR REAR AXLE SERVICE.
12. Clean support plate with Mopar Brake parts Gleaner (p/n 04549623). Then, smooth brake shoe contact pads with a wire brush or emery cloth.
13. Lubricate adjuster lever, anchor pins, and brake shoe contact pads with Mopar Brake Lubricant (p/n 04796269).
14. Clean and check operation of adjuster screw assembly. Replace assembly if threads are heavily rusted, corroded, or damaged. Make sure each screw assembly rotates freely then, lubricate the adjuster screw threads with Mopar Spray White Lube (p/n 04318066).
15. Attach parking brake lever to new secondary brake shoe (from p/n 04886328AA Rear Brake Lining Set). Use new E-clip to secure lever to shoe. If lever is secured with a U-clip, pinch new clip together with channel lock piers to secure it.
16. Attach parking brake cable to parking brake lever.
17. Install secondary brake shoe and adjuster lever as follows:
a. Insert new secondary brake shoe hold-down pin (from package p/n 04761560) through support plate.
b. Position secondary brake shoe on support plate and insert new pin (from package p/n 04761560) through shoe.
c. Position adjuster lever on brake shoe and insert new hold-down spring inner retainer (from package p/n 04761560) into lever and shoe. Inner retainer has a shoulder on it which seats in lever and shoe.
d. Install new hold-down spring (from package p/n 04761560) over pin and seat it in inner retainer. Then, install and seat hold-down spring outer retainer on pin with hold-down spring tool.
18. Install adjuster lever spring between brake shoe and lever. Be sure spring is seated on lever tang.
19. Attach shoe spring to secondary brake shoe. Long end of spring goes into secondary shoe.
20. Instal oval shaped spring onto parking brake strut and engage spring end of strut into secondary brake shoe.
21. Install primary brake shoe (from p/n 04886328AA Rear Brake Lining Set) onto support plate. Use new hold-down spring, pin, and retainers (from package p/n 04761560) to secure shoe. Be sure parking brake strut is seated in both brake shoes.
22. Install adjuster screw assembly. Be sure star wheel is positioned adjacent to adjuster lever and that notches in adjuster screw are properly seated on brake shoes.
23. Attach shoe spring to primary brake shoe. Use brake spring pliers and long screwdriver to seat spring in shoe.
24. Install shoe guide plate onto anchor pin.
25. Attach adjuster spring to spring retainer at the top of the adjuster lever then, seat spring on anchor pin with brake spring pliers.
26. Install secondary brake shoe return spring. Attach short end of spring to brake shoe then, hook opposite end on adjuster spring. Use brake spring pliers or a long shank screwdriver to engage return spring in adjuster spring.
27. Install primary brake shoe return spring.
28. Check component installation. Be sure adjuster screw, wheel cylinder links, and park brake struts are all seated in brake shoes.
29. Adjust brake shoe to drum clearance. Refer to the 1997 Ram Truck Service Manual (Publication No. 81-370-7108), pages 5-40 and 5-41 "ADJUSTMENT WITH BRAKE GAUGE," for information regarding proper rear brake adjustment procedures.
30. Install brake drums.
31. Install wheel and tire assemblies. Refer to the 1997 Ram Truck Service Manual (Publication No. 81-377-7108), pages 22-8 through 22-10 for information regarding proper wheel installation and lug nut torques.
32. Repeat steps 3 through 31 for opposite side of vehicle.
33. Lower vehicle down and install any wheel covers that were removed earlier.