Parking Brake Actuator

This procedure covers the removal and replacement of the parking brake actuator (lever assembly) on a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Parking brake actuator assembly × 1 — Use OEM specification
• Parking brake actuator mounting bolts (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and place transmission in PARK
2. Apply wheel chocks to FRONT wheels only (do not rely on parking brake)
3. Raise rear of vehicle using proper jacking points and support on jack stands
4. Allow vehicle to cool completely if recently driven
5. Disconnect negative battery cable to prevent accidental electrical shorts
6. Remove driver side lower dash trim panel and knee bolster for access to upper actuator mounting area

Procedure

1. 1

   Release parking brake tension
   Locate the parking brake actuator, which is a foot-operated pedal assembly mounted on the driver side lower left kick panel/firewall area inside the cab. Ensure the pedal is in the fully released (up) position using the release handle. Verify there is no tension on the parking brake cables by checking that the pedal moves freely without resistance.
2. 2

   Access rear parking brake cables
   From underneath the vehicle near the rear axle, locate the parking brake cable equalizer where the two rear cables meet the front cable. Note the cable routing and take reference photos. The equalizer is typically located just forward of the rear axle on the driver side frame rail.
3. 3

   Disconnect cable at equalizer
   At the cable equalizer, compress the cable housing retaining tangs and slide the cable housing out of the mounting bracket. Disconnect the cable end from the equalizer by unhooking it from the clevis or pin connection. Allow the rear cables to hang free. Note the exact routing for reinstallation.
4. 4

   Trace front cable to actuator
   Follow the front parking brake cable from the equalizer forward along the frame rail and through the cab floor. The cable enters the cab through a grommet in the floor pan on the driver side. Verify the cable path is clear and note any clips or retainers holding the cable.
5. 5

   Remove actuator mounting fasteners
   Inside the cab, locate the parking brake actuator mounting bolts. There are typically 3-4 bolts securing the actuator bracket to the cab floor and firewall structure. Remove all mounting bolts using the appropriate socket. Support the actuator assembly as you remove the final bolt to prevent it from falling.
6. 6

   Disconnect cable from actuator
   With the actuator loose, locate where the parking brake cable connects to the actuator lever mechanism. This is typically a clevis pin or ball-and-socket connection. Remove any retaining clip or cotter pin, then disconnect the cable end from the actuator lever. Note the orientation of the cable connection.
7. 7

   Remove actuator assembly
   Carefully maneuver the parking brake actuator assembly out of the cab area. You may need to rotate or angle the assembly to clear surrounding components. Inspect the mounting points and cable connection points for damage or excessive wear.
8. 8

   Inspect and prepare new actuator
   Compare the new parking brake actuator to the old unit to verify correct replacement. Check that all mounting holes align and that the cable connection point is identical. Verify the ratcheting mechanism operates smoothly and the release handle functions properly. Apply a small amount of cable lubricant to the cable connection point on the new actuator.
9. 9

   Install new actuator
   Position the new parking brake actuator/pedal assembly in the mounting location, ensuring proper orientation with the foot pedal and release handle accessible from the driver position. Start all mounting bolts by hand before tightening any of them. Ensure the actuator bracket sits flush against all mounting surfaces.
10. 10

    Tighten actuator mounting bolts
    Tighten all parking brake actuator mounting bolts in a cross-pattern to ensure even clamping. Since factory torque specifications should be confirmed against service information, tighten firmly using hand tools only (not impact tools) until bolts are snug and the actuator is solidly mounted without movement. Do not rely on a guessed torque value; verify the correct factory torque specification before final tightening.
11. 11

    Connect cable to actuator
    Attach the parking brake cable end to the new actuator lever mechanism. Ensure the cable end is fully seated in the clevis or ball socket. Install any retaining clips or cotter pins to secure the connection. Verify the cable moves freely without binding when the actuator lever is operated.
12. 12

    Reconnect cable at equalizer
    From underneath the vehicle, route the front parking brake cable back to the equalizer following the original path. Reconnect the cable end to the equalizer, ensuring it is properly seated. Insert the cable housing into the mounting bracket until the retaining tangs click into place. Verify the cable is not twisted or kinked.
13. 13

    Adjust cable tension
    Inside the cab, depress the parking brake pedal to the first click position. The rear brake shoes should just begin to contact the drums. If tension is too loose or too tight, adjustment may be made at the equalizer by threading the cable adjuster nut in or out. Some models have an adjustment nut at the equalizer; others require cable replacement for proper adjustment. Consult service information for specific adjustment procedures if needed.

Reassembly

1. Reinstall driver side knee bolster and lower dash trim panels, ensuring all clips are properly seated
2. Reconnect negative battery cable
3. Remove jack stands and lower vehicle to ground
4. Remove wheel chocks from front wheels

Verification

• With engine running and transmission in PARK on level ground, pull parking brake lever fully up and count the clicks. Proper adjustment is typically 3-5 clicks for full engagement
• Attempt to move vehicle with parking brake engaged and transmission in NEUTRAL (remain in driver seat with foot on service brake). Vehicle should not roll
• Release parking brake and verify both rear wheels rotate freely by hand with no dragging
• Test drive vehicle at low speed in a safe area and verify parking brake holds vehicle on a moderate incline
• Verify parking brake warning light on instrument cluster illuminates when lever is pulled and extinguishes when released
• Inspect underneath vehicle for any cables rubbing or contacting exhaust or driveline components
• If parking brake does not hold adequately, rear brake shoe adjustment or replacement may be required in addition to actuator replacement

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