STANDARD PROCEDURE - BLEEDING RAM Pickup 3500

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. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8.
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.

Scheme 54

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 (5) from master cylinder (3).
3. Remove mounting nuts (4) from the master cylinder.
4. Remove the master cylinder (3).
5. Remove the return hose and the two pressure lines (2) from the hydraulic booster.
6. From inside the vehicle remove the booster push rod clip, washer and rod remove from the brake pedal.
7. Remove the brake lamp switch. Refer to «SWITCH, Stop Lamp , Removal»(ref-457789-S34637861412012030200000) .
8. Remove the mounting nuts from the hydraulic booster and remove the booster.

Note. 1500 shown in illustration, others similar.

Scheme 55

1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
2. Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
3. Remove the tire and wheel assembly.
4. Compress the disc brake caliper (6).
5. Remove the banjo bolt (4) and discard the copper washers.
6. Remove the caliper slide pin bolts (2).
7. Remove the disc brake caliper (1) from the caliper adapter (2).

Scheme 56

1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
2. Raise and support vehicle.
3. Remove the wheel and tire assembly.
4. Drain small amount of fluid from master cylinder brake reservoir with suction gun.
5. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper.
6. Remove the caliper slide bolts (3).
7. Remove the caliper (6) from vehicle.

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

1. Drain the brake fluid from caliper.
2. C-clamp (2) a block of wood (1) over one piston. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury.
3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal.
4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.
5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore.
6. Move the padded piece of wood in front of the other piston.
7. Remove the second piston using the same procedure with short bursts of low pressure air .
8. Remove piston dust boots (2) by hand. CAUTION: Do not scratch piston bore while removing the seals.
9. Remove the lip seal from the groove (4) with a pick tool (3).
10. Remove piston seals (2) from caliper (1) by hand.

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. Drain the brake fluid from caliper.
2. C-clamp (2) a block of wood (1) over one piston.
3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY.
4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.
5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore.
6. Move the padded piece of wood in front of the other piston.
7. Remove the second piston using the same procedure with short bursts of low pressure air .
8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals.
9. Remove piston seals (3) from caliper (1).
10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1).
11. Remove caliper bleed screw.