OEM 2002 Dodge Ram 3500 Brake Booster

2002 Dodge Ram 3500 Brake Booster Parts and Q&A

• Q: How to Maintain a Brake Booster System on 2002 Dodge Ram 3500?

  A: Whenever replacing the hydraulic brake booster due to contaminated power steering fluid, it's necessary to flush the power steering system before removal. Turn off the engine, press the brake five times and then release it. After that, loosen the brake lines on the master cylinder and remove the mounting nuts. Take off the bracket from both the hydraulic booster lines and the studs that connect the master cylinder. Once done, take out the master cylinder. After that, pull out the return hose and the two pressure lines from the hydraulic booster. Unfasten the booster push rod clip, remover the washer and rod from the brake pedal and then take out the nuts from the booster before unbolting the hydraulic booster. At installation time, fit the hydraulic booster and secure it with tightened mounting nuts set at 28 Nm (21 ft. lbs.). Secure the booster push rod, washer and clip onto the brake pedal in place and fit the master cylinder onto the studs. Fasten the nuts with 23 Nm (17 ft. lbs.) of torque. Reattach the brake lines to the master cylinder using torque values between 19 and 200 Nm (170 and 200 inch lbs.) and then fit the hydraulic booster line bracket over the cylinder studs. Connect the master cylinder mounting nuts to 23 Nm (17 ft. lbs.), then tie the hose connections for the hydraulic booster to the bracket and booster, tightening all to 41 Nm (30 ft. lbs.). Before you begin, look at the O-rings on the pressure line fittings to make sure they are fine and change them if needed. Join the return hose to the booster; bleed all the air from the base brake system; and add Mopar power steering fluid or any equal product to the power steering pump, neither Atf nor overfilled. Always remember to bleed the hydraulic booster.