Ram B1500, B2500, B3500, 1999-2003

Hydraulic Brake Booster

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Hydraulic brake boosters are used on trucks with diesel engines.

Removal & Installation




CAUTION
The accumulator contains high-pressure gas. Do NOT carry the booster by the accumulator or drop the unit on the accumulator.

  1. With the engine OFF , depress the brake pedal several times to discharge the accumulator.
  2.  
  3. Remove the master cylinder.
  4.  
  5. Remove the return hose and the two pressure lines from the booster.
  6.  
  7. Remove the steering column knee bolster for access to the booster mounting nuts, if necessary.
  8.  
  9. Remove the clip securing the booster push rod to the brake pedal and disconnect the push rod from the pedal.
  10.  
  11. Remove the nuts from the booster mounting studs.
  12.  
  13. Remove the booster.
  14.  

To install:


NOTE
If the booster is being replaced, ensure that the replacement unit is identical to the original. Refer to identification code letters stamped on the forward face.

  1. Reverse the removal procedure.
  2.  
  3. Tighten the mounting nuts to 21 ft. lbs. (28 Nm).
  4.  
  5. Inspect the O-rings on the pressure line fittings to ensure they are in good condition. Replace them if questionable.
  6.  
  7. Tighten the pressure lines to 21 ft. lbs. (28 Nm).
  8.  
  9. The remainder of the procedure is the reverse of removal.
  10.  
  11. Bleed the booster after installation is completed:
    1. Fill the power steering pump reservoir.
    2.  
    3. Disconnect the fuel shutdown relay and crank the engine for several seconds.
    4.  
    5. Check the fluid level and add if necessary.
    6.  
    7. Reconnect the fuel shutdown relay and start the engine.
    8.  
    9. Turn the steering wheel slowly from lock to lock.
    10.  
    11. Stop the engine and discharge the accumulator by depressing the brake pedal five times.
    12.  
    13. Start the engine and turn the steering wheel slowly from lock to lock twice.
    14.  
    15. Shut off the engine and make a final check of fluid level.
    16.  

  12.  



Click image to see an enlarged view

Fig. Power brake hydraulic booster lines



Click image to see an enlarged view

Fig. Power brake hydraulic booster mounting nuts

 
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