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TSB 05-003-04

Brake Shudder or Vibration

Visit Geno's Garage for Truck accessories.

Date: June 8, 2004

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-008-03, DATED
NOVEMBER 28, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES.  

Models: 2003 (DR) Ram Truck (1500 Series Only)

Overview:
This bulletin involves installing brake pads, calipers, resurfacing the rotors and checking rotor
runout.

Symptom/Condition:
The vehicle may exhibit pulsation or vibration in the brake pedal and/or steering wheel when
the brakes are applied. The condition is most noticeable at speed over 50 MPH but can occur
at lower speeds.

Diagnosis:
If the customers indicate that the condition is present, perform the Repair Procedure.

Parts Required:

Qty.	Part No.	Description
1	05080556AF	Brake Pads - Vehicles built prior to March 6, 2003 (MDH 0603XX)
1	05139733AA	Brake Pads - Vehicles built after March 6, 2003 (MDH 0603XX)
1	05134582AB	Caliper , Right (2003 Only)
1	05134583AB	Caliper, Left (2003 Only)

NOTE: 2004 vehicles are already equipped with the calipers listed above. Do not
replace calipers on 2004 vehicles.

Special Tools/Equipment Required:

Repair Procedure: 

1.	Inspect the front brakes for any signs of abnormal wear or damage. Repair as necessary.
2.	Resurface the front brake rotors with a DaimlerChrylsler approved on-car brake lathe. If an on-car lathe is not available at the dealership, the rotor resurfacing must be sublet to a facility with an approved on car lathe.
3.	Remove the calipers.
4.	Clean the caliper adapter and lubricate the adapter and anti-rattle springs with MOPAR brake grease.
5.	Install new calipers, p/n’s 05134582AB and 05134583AB.
6.	Replace the front pads and anti-rattle springs with the appropriate part number listed in the Parts Required Section above.
7.	Bleed the system.
8.	Mark one wheel stud on each side with a dab of paint or suitable marker.
NOTE: Wheel stud torque is critical to the success of the repair. the following procedure is intended to identify excessive rotor distortion which could be caused by improper wheel stud torque.
9.	Install the wheel and pre-tighten the lug nuts in a cross pattern to: 70 Nm (50 ft. lbs.) then final the lug nuts in a cross pattern to: 183 Nm (135 ft. lbs.) and mark the wheel at the same location as the marked wheel stud.
10.	Set up a dial indicator to measure mounted rotor runout . Place the dial indicator plunger against the inner machined rotor face, visible between the brake caliper and the front splash shield(Fig. 1). Rotate the wheel and tire assembly two turns and take runout measurement. If the measurement is less than .050 mm (.002 in.) no further action is required. If the measurement is greater than .050 mm (.002 in.) remove the lug nuts and relocate the wheel one stud clockwise, tighten the lug nuts as described in step 6 and check the runout again. Do not remove any brake parts. Repeat step 7 for each wheel location until you achieve the lowest mounted runout. Minimum mounted rotor runout will be achieved by moving the wheel, not the rotor.
10.	Repeat the mounted lateral runout check for the other rotor.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: May 3, 2004