Brake Caliper - Front

This procedure covers removal and replacement of the front brake caliper on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine, including bleeding the brake system.

Warnings

Tools required

Parts

• Front brake caliper (specify left or right) × 1 — Use OEM specification or quality aftermarket
• Copper brake line washers × 2 — Use OEM specification
• Brake fluid DOT 3 × 1 — DOT 3 specification

Fluids

• DOT 3 brake fluid — 0.25 qt

Preparation

1. Park vehicle on level, paved surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Open brake fluid reservoir cap slightly to relieve vacuum and allow piston retraction (do not remove completely)
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Lift front of vehicle using floor jack at manufacturer-specified lift points on frame
6. Support vehicle securely on jack stands rated for at least 3 tons each, positioned under frame rails
7. Remove front wheel completely
8. Verify vehicle is stable before working underneath

Procedure

1. 1

   Inspect brake system and caliper
   Visually inspect the brake caliper, rotor, brake line, and rubber hose for damage, leaks, or excessive wear. Check brake pad thickness through caliper inspection window. Note the routing of the brake line for proper reinstallation. Take photos if helpful for reference during reassembly.
2. 2

   Remove brake line from caliper
   Place a drain pan beneath the caliper to catch brake fluid. Using an appropriately sized socket or wrench, carefully loosen and remove the brake line banjo bolt connecting the flexible brake hose to the caliper. Immediately plug the brake line opening with a rubber cap or clean rag to minimize fluid loss and prevent contamination. Remove and discard both copper washers from the banjo bolt (one on each side of the fitting).
3. 3

   Remove caliper mounting bolts
   Locate the two caliper bracket bolts that secure the caliper bracket to the steering knuckle. Verify the correct socket size against factory documentation; these are accessed from the rear of the caliper assembly. Using a 19mm socket and breaker bar if necessary, remove both caliper bracket bolts completely. These bolts are torqued to high specification and may require significant force to break loose.
4. 4

   Remove caliper and bracket assembly
   Carefully slide the entire caliper and bracket assembly off the brake rotor. If the caliper is stuck to the rotor due to corrosion or pad wear, gently tap the caliper body with a rubber mallet to free it. Remove the assembly completely from the vehicle. Keep the caliper upright as much as possible to minimize brake fluid spillage.
5. 5

   Inspect mounting surfaces and hardware
   Clean the caliper mounting surface on the steering knuckle using a wire brush and brake parts cleaner. Remove any rust, corrosion, or debris that could prevent proper caliper seating. Inspect the brake rotor for excessive wear, scoring, or warping. If installing a remanufactured caliper, ensure brake pads are properly seated in the caliper bracket and slide pins are lubricated if applicable.
6. 6

   Install new caliper assembly
   Position the new caliper and bracket assembly onto the steering knuckle, sliding it over the brake rotor. Align the mounting bolt holes in the bracket with the threaded holes in the knuckle. Ensure the caliper bleeder screw is positioned at the top for proper bleeding. If using threadlocker, apply a small amount to the caliper bracket bolt threads now.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
7. 7

   Install and torque caliper bracket bolts
   Install both caliper bracket bolts and hand-tighten them to ensure proper thread engagement and alignment. Using a torque wrench, tighten both bolts to the factory-specified value (verify in service documentation for this model year — typically in the 130-150 lb-ft range for the caliper bracket-to-knuckle bolts). These bolts are CRITICAL to brake system safety and must be torqued accurately. Double-check both bolts reach proper specification.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Connect brake line to caliper
   Install one new copper washer onto the banjo bolt, then position the brake line banjo fitting onto the caliper inlet port. Install the second new copper washer on the outside of the banjo fitting, then thread the banjo bolt through the assembly by hand. Ensure the brake line is not twisted or kinked and follows the original routing path.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Torque brake line banjo bolt
   Using a torque wrench with an appropriately sized socket or wrench, tighten the brake line banjo bolt to the factory-specified value (verify in service documentation). This is a CRITICAL torque specification - overtightening can crack the caliper body or damage the copper washers, while undertightening will cause brake fluid leaks. Verify there are no visible leaks around the connection.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
10. 10

    Bleed brake caliper
    Attach a clear bleeder hose to the caliper bleeder screw and route the other end into a catch bottle partially filled with clean brake fluid. Have an assistant slowly pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 to 1/2 turn using the correct size wrench (verify size on the actual bleeder screw) while assistant maintains pedal pressure. Close the bleeder screw before the pedal reaches the floor. Repeat this process 5-8 times until no air bubbles appear in the clear hose and only clean fluid flows. Maintain brake fluid reservoir level throughout bleeding process - do not allow it to run dry.
    Torque spec

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

    Final bleeder screw torque
    After bleeding is complete and while the bleeder hose is still attached, tighten the bleeder screw to 10 Nm (7 lb-ft) using a torque wrench. Do NOT overtighten as the bleeder screw threads are easily stripped. Remove the bleeder hose and wipe away any spilled brake fluid from the caliper and surrounding area.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Check brake fluid level
    Top off the brake fluid reservoir to the MAX line with fresh DOT 3 brake fluid from a sealed container. Securely install the reservoir cap. Wipe any spilled fluid from the reservoir and master cylinder area.
13. 13

    Reinstall wheel
    Clean the wheel hub face and wheel mounting surface with a wire brush. Install the wheel onto the hub, threading lug nuts by hand to ensure proper seating. Tighten lug nuts in a star pattern to snug, but do not fully torque yet.
14. 14

    Lower vehicle and final torque
    Carefully lower the vehicle from jack stands using the floor jack until the tire contacts the ground but most weight is still supported. Torque wheel lug nuts in a star pattern to manufacturer specification (verify exact value in owner's manual for this model year and wheel configuration). Fully lower vehicle and remove jack. Repeat entire procedure for opposite side if replacing both calipers. Torque wrench with capacity of at least 150 lb-ft (200 Nm) to cover caliper bracket bolts and lug nuts is required. A tool range with max ~110 lb-ft is insufficient for the caliper bracket bolts and lug nuts (135 lb-ft), which exceed that wrench's capacity.

Reassembly

1. Ensure all brake hardware is clean and properly seated before final installation
2. New copper washers must be installed on both sides of the banjo bolt fitting
3. Threadlocker is recommended but not required on caliper bracket bolts due to high torque specification
4. If brake pads were replaced, expect some initial brake pedal travel until pads seat to rotor surface

Verification

• With engine off, pump brake pedal firmly 10-15 times. Pedal should become firm and hold pressure. If pedal remains soft or sinks, air remains in system or there is a leak - do not drive vehicle
• Inspect all brake line connections for leaks while assistant applies firm pedal pressure
• Check brake fluid reservoir level is at MAX line
• Start engine and verify brake warning light is off
• Test brakes at low speed (under 5 mph) in a safe area to verify proper function before normal operation
• During first 50-100 miles, expect slight brake noise as new caliper/pads bed in to rotor surface
• Re-check all torque specifications and brake fluid level after test drive
• If brake pedal feels soft, travels too far, or vehicle pulls to one side during braking, do not drive and seek professional service immediately

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