Brake Caliper Bracket

This procedure covers removal and replacement of the brake caliper bracket (also called caliper mounting bracket) on the front or rear axle of a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Brake caliper bracket (front or rear as needed) × 1 — Use OEM specification or quality equivalent
• Brake pads (if worn or damaged) × 1 — Use OEM specification
• Brake hardware kit (anti-rattle clips, shims) × 1 — Included with quality brake pad sets
• Copper crush washers for banjo bolt × 2 — Use OEM specification

Fluids

• DOT 3 brake fluid — 1 qt

Preparation

1. Park vehicle on level ground and set parking brake firmly
2. Chock the rear wheels if working on front brakes, or front wheels if working on rear brakes
3. Loosen wheel lug nuts while vehicle is on the ground but do not remove
4. Lift vehicle with floor jack at appropriate jacking point and secure with jack stands on frame rails
5. Remove wheel completely
6. Clean the brake assembly area with brake cleaner spray to remove dirt and debris
7. Place a catch pan under the brake assembly to capture any brake fluid
8. Have DOT 3 brake fluid ready for refilling and bleeding after reassembly

Procedure

1. 1

   Compress caliper piston and remove caliper
   Before removing any brake lines, slowly compress the caliper piston back into its bore using a C-clamp or brake piston tool. This reduces fluid spillage and makes caliper removal easier. Remove the caliper slide pin bolts (typically 13mm or 15mm) and carefully lift the caliper off the bracket. Support the caliper with wire or a bungee cord hung from the suspension or frame. Do NOT let the caliper hang by the brake hose as this can damage the hose internally.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect brake hose from caliper (if replacing bracket only)
   If you are only replacing the bracket and reusing the caliper, you must disconnect the brake hose. Place a catch pan underneath. Using a line wrench, carefully loosen the brake hose banjo bolt at the caliper. Have rags ready to catch fluid. Once loose, remove the bolt completely and separate the hose from the caliper. Plug the hose end immediately with a rubber cap or clean rag to minimize fluid loss and contamination. Note the position of the copper crush washers on both sides of the banjo fitting - these must be replaced with new washers.
   ⚠Brake fluid will drain from the open line. Keep catch pan in place and have rags ready.
   Torque spec

   Brake Hose Banjo Bolt41 Nm (30 lb-ft)
3. 3

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket by sliding them out of the bracket. Note their orientation and position. Remove any anti-rattle clips, shims, or pad retention hardware from the bracket. Keep track of how these components are positioned for reassembly. Inspect pads for uneven wear which may indicate a previous bracket or caliper issue.
4. 4

   Remove caliper bracket mounting bolts
   Locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle (front) or axle flange (rear). These are typically 18mm or 21mm bolts and are very tight. Use a breaker bar if necessary to break them loose. Verify the correct torque specification for your specific model year against the factory service manual, as the front bracket bolt torque differs between the 1994-2002 (2nd gen) and 2003-2007 (3rd gen) platforms. Remove both bolts completely and remove the bracket from the vehicle. Inspect the mounting bolt threads and knuckle/axle threads for damage.
   ⚠These bolts are extremely tight from the factory. Use a long breaker bar and ensure the socket is fully seated to avoid rounding the bolt heads.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
5. 5

   Inspect mounting surfaces and prepare new bracket
   Thoroughly clean the caliper mounting surface on the steering knuckle or axle flange using a wire brush. Remove all rust, corrosion, and debris. Inspect the mounting bolt holes for thread damage or stripping. Clean the mounting bolt threads with a wire brush. Inspect the new caliper bracket for any shipping damage or defects. Clean the bracket mounting surface and bolt holes with brake cleaner.
6. 6

   Install new caliper bracket
   Position the new caliper bracket onto the steering knuckle or axle flange, ensuring proper alignment with the rotor. Apply medium-strength thread locker to the bracket mounting bolt threads as recommended. Start both bracket mounting bolts by hand to ensure proper thread engagement. Torque the bracket mounting bolts to the factory specification for your specific model year and axle, using a cross pattern. Confirm the exact value in the FSM, as it differs between the 1994-2002 and 2003-2007 platforms. Verify the bracket is secure and does not move.
   ⚠️Improperly torqued bracket bolts can result in catastrophic brake failure. Use a calibrated torque wrench.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
7. 7

   Install brake hardware and pads
   Install new anti-rattle clips, shims, and pad retention hardware into the new bracket according to the hardware kit instructions. Apply a thin layer of silicone brake grease to the pad backing plate edges where they contact the bracket (do NOT get grease on friction surfaces). Install the brake pads into the bracket in their correct positions, ensuring they slide smoothly in the bracket channels.
8. 8

   Reconnect brake hose to caliper
   Install NEW copper crush washers on both sides of the brake hose banjo fitting. Position the banjo fitting into the caliper inlet port with proper orientation (ensure hose routing will not interfere with suspension or tire). Install the banjo bolt by hand first, then torque to the factory specification (verify in the FSM, typically in the 23-41 Nm / 17-30 lb-ft range for this application) using a torque wrench. Do not overtighten as this can crack the caliper casting or collapse the washers excessively.
   ⚠️Always use NEW copper crush washers. Reusing old washers will result in brake fluid leaks and potential brake failure.
   Torque spec

   Brake Hose Banjo Bolt41 Nm (30 lb-ft)
9. 9

   Apply grease to slide pins and reinstall caliper
   Clean the caliper slide pins thoroughly with brake cleaner. Apply a generous coat of silicone brake grease to the slide pin shafts (not the threads). Position the caliper over the brake pads and bracket, aligning the slide pin bolt holes. Install the slide pin/guide pin bolts and torque to the factory specification (verify in the FSM for your model year and caliper type). Verify the caliper slides freely on the pins before proceeding.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Bleed brake system
    The brake system now contains air and must be bled. Check the master cylinder reservoir and fill to MAX line with DOT 3 brake fluid. Starting with the wheel furthest from the master cylinder (typically right rear, then left rear, then right front, then left front), attach a clear hose to the bleeder screw and submerge the other end in a container of clean brake fluid. Have an assistant pump the brake pedal 3-5 times and hold. Open the bleeder screw 1/2 turn and allow fluid and air to escape, then close the bleeder before the pedal reaches the floor. Torque bleeder screw to 10 Nm (7 lb-ft). Repeat until no air bubbles appear. Check reservoir level frequently and never let it run dry. Never reuse brake fluid that has been bled from the system. Always use fresh DOT 3 fluid from a sealed container (verify DOT 3 specification against the vehicle's master cylinder reservoir cap marking).
    ⚠️If the brake pedal does not return to firm pressure after bleeding, do NOT drive the vehicle. Air remains in the system or there is a component failure.
    ⚠Never reuse brake fluid that has been bled from the system. Always use fresh DOT 3 fluid from a sealed container.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheel and perform final torque
    Clean the wheel mounting surface on the hub. Position the wheel onto the hub and start all lug nuts by hand. Torque the lug nuts to the factory specification (typically approximately 165-176 lb-ft / 225-240 Nm for the Ram 2500 — verify the exact value in the FSM) in a star pattern to ensure even clamping force. Lower the vehicle from jack stands and perform a final torque check on the lug nuts with the vehicle on the ground.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all brake line connections are tight and leak-free
2. Verify caliper slide pins move freely and are properly greased
3. Confirm brake pads are correctly seated in the bracket with all hardware installed
4. Double-check all torque specifications have been met, especially bracket bolts and lug nuts
5. Top off brake fluid reservoir to MAX line with fresh DOT 3 brake fluid

Verification

• With engine off, pump brake pedal multiple times - it should become firm and hold pressure. If pedal goes to floor, system is not properly bled or has a leak
• Inspect all brake connections for fluid leaks while assistant holds firm pressure on brake pedal
• Start engine and verify brake pedal remains firm (pedal may drop slightly as brake booster activates, this is normal)
• Test drive in a safe area at low speed (under 15 mph) and verify brakes apply evenly without pulling to one side
• Perform several moderate brake applications from 30-40 mph in a safe area to seat the pads and verify proper operation
• After test drive, recheck all connections and torque specifications, particularly wheel lug nuts
• Check brake fluid level and top off if needed - fluid level will drop as pads wear in
• Inspect for any brake fluid leaks around caliper, bracket, and hose connections after 50-100 miles of driving

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