Brake Caliper - Rear

Replace the rear brake caliper on a 2005 Dodge Viper, including bleeding the hydraulic system and verifying proper brake operation.

Warnings

Tools required

Parts

• Rear brake caliper × 1 — Use OEM specification
• Copper crush washers for brake line banjo bolt × 2 — Two washers per banjo bolt fitting
• Brake fluid DOT 4 × 1 — Use OEM specification

Fluids

• DOT 4 brake fluid — 1 qt

Preparation

1. Park vehicle on level ground and apply parking brake firmly.
2. Place wheel chocks in front of both front wheels.
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on the ground.
4. Raise rear of vehicle with floor jack and support securely on jack stands positioned under manufacturer-approved jacking points on the chassis.
5. Remove rear wheel completely.
6. Open hood and locate brake master cylinder reservoir. Check fluid level and remove approximately half the fluid using a turkey baster or fluid transfer pump to prevent overflow when compressing caliper pistons.
7. Have a helper available to assist with brake bleeding procedure.

Procedure

1. 1

   Position brake fluid catch container
   Place a drain pan or brake fluid catch container beneath the rear brake caliper to catch fluid that will drain when the brake line is disconnected. Have shop towels ready to contain spills.
2. 2

   Disconnect brake hydraulic line
   Locate the brake hose connection on the caliper body. Verify the fitting type against OEM service documentation — the 2005 Viper Brembo caliper may use a threaded flare fitting rather than a banjo bolt. Use the correct line wrench for the fitting and loosen the connection. Allow brake fluid to drain into the catch container. Once the bolt is removed, immediately plug the open brake line with a rubber cap or wrap with plastic and tape to prevent further fluid loss and contamination. Discard the old copper crush washers—do not reuse them.
   ⚠Brake fluid will begin draining immediately when the banjo bolt is loosened. Keep the catch container positioned directly below the connection.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper mounting bolts that secure the fixed caliper to the rear knuckle/mounting flange. Verify the bolt head size against OEM service documentation before selecting a socket. Using an 18mm socket and ratchet or breaker bar, remove both caliper bracket bolts completely. The caliper and bracket assembly will now be free from the hub.
   ⚠The caliper and bracket assembly is heavy. Support it with one hand while removing the second bolt to prevent it from falling.
4. 4

   Remove caliper assembly
   Carefully lift the caliper and bracket assembly away from the brake rotor. The brake pads will remain with the caliper or fall free—keep track of them if reusing. Remove the entire assembly from the vehicle and set aside in a safe location.
5. 5

   Inspect mounting surfaces and hardware
   Inspect the caliper mounting bracket location on the hub for debris, corrosion, or damage. Clean the mounting surface with a wire brush if necessary. Check the brake rotor condition and thickness. Verify that the pad retaining pins/clips and abutment surfaces are clean and in good condition if reusing pads, as appropriate for the fixed-caliper design.
6. 6

   Prepare new caliper
   Unpack the new rear brake caliper. The fixed Brembo caliper is a one-piece unit and typically has no separate mounting bracket to transfer; confirm the replacement caliper matches the original per OEM service documentation. Ensure the new caliper bleeder screw is accessible and not damaged. Because this is a fixed opposed-piston Brembo caliper, do not use a C-clamp. Verify the pistons are seated per OEM procedure and install the pads/caliper as directed by the service manual.
7. 7

   Install caliper assembly to hub
   Position the new caliper assembly over the brake rotor, aligning the mounting bracket bolt holes with the hub mounting points. Apply medium-strength threadlocker to the threads of both caliper bracket mounting bolts. Insert both bolts and hand-tighten. Using an 18mm socket and torque wrench, tighten both caliper bracket bolts to specification in a cross-pattern.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Connect brake hydraulic line
   Remove the protective cap or plug from the brake line. Position two new copper crush washers on the banjo bolt (one on each side of the banjo fitting). Align the brake line banjo fitting with the threaded port on the caliper body. Insert the banjo bolt through the fitting and thread it into the caliper by hand. Using a 13mm wrench and torque wrench, tighten the banjo bolt to specification.
   ⚠️Verify that both new copper crush washers are in place before tightening the banjo bolt. Missing or reused washers will cause brake fluid leaks.
   Torque spec

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

   Bleed rear brake caliper
   Attach a clear vinyl hose to the caliper bleeder screw and place the other end into a container partially filled with fresh DOT 4 brake fluid. Have a helper sit in the driver's seat. Refill the brake master cylinder reservoir to the MAX line with fresh DOT 4 fluid. Instruct the helper to pump the brake pedal 5-7 times and hold firm pressure. Bleed each bleeder screw on the fixed caliper (Brembo fixed calipers typically have more than one); using the correct-size bleeder wrench, open the bleeder screw 1/2 turn. Fluid and air will flow through the hose. When flow stops and the pedal reaches the floor, close the bleeder screw before the helper releases the pedal. Repeat this process until no air bubbles appear in the hose and only clean fluid flows. Check and refill the master cylinder reservoir frequently to prevent it from running dry. After bleeding is complete, tighten the bleeder screw to specification. Note: Never allow the master cylinder reservoir to run empty during bleeding. Introducing air into the hydraulic system will require re-bleeding; note the 2005 Viper is not equipped with ABS.
   ⚠️Never allow the master cylinder reservoir to run empty during bleeding. Introducing air into the ABS hydraulic unit requires specialized scan tools to purge.
   ⚠The bleeder screw is brass and easily damaged. Do not overtighten.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Reinstall wheel
    Position the wheel onto the hub and hand-thread all lug nuts. Using a lug wrench or impact wrench, tighten the lug nuts in a star pattern until snug but not fully torqued. Lower the vehicle from the jack stands until the wheel contacts the ground but the suspension is not fully loaded. Torque the lug nuts to the manufacturer's specification (typically 100 lb-ft for the Viper) in a star pattern. Fully lower the vehicle and remove jack stands.
    ℹ️Final lug nut torque should be verified with a torque wrench after the vehicle is on the ground.
11. 11

    Verify master cylinder fluid level
    Open the hood and check the brake master cylinder reservoir. Top off with fresh DOT 4 brake fluid to the MAX line. Install the reservoir cap securely.

Reassembly

1. Reinstallation follows the reverse order of removal, with critical attention to torque specifications and brake bleeding procedure.
2. Always use new copper crush washers on the brake line banjo bolt—never reuse old washers.
3. Apply medium-strength threadlocker to caliper bracket mounting bolts as recommended.
4. Bleed the brake system until all air is purged and only clean, bubble-free fluid emerges from the bleeder screw.
5. Torque all fasteners to specification using a calibrated torque wrench.

Verification

• With the engine off, pump the brake pedal repeatedly. The pedal should become firm after 3-5 pumps and hold steady pressure. A soft or sinking pedal indicates air in the system—repeat bleeding procedure.
• Start the engine. The brake pedal should drop slightly as the power brake booster engages, then remain firm.
• Inspect the caliper and brake line connections for any signs of fluid leakage. Wipe all connections dry with a clean shop towel and recheck after pumping the brakes.
• Perform a low-speed test drive in a safe area. Apply brakes gently at 5-10 mph to verify proper caliper engagement and absence of pulling to one side.
• Perform a firm stop from 25-30 mph in a safe area to verify full braking power. The vehicle should stop in a straight line without pulling.
• After test drive, recheck brake fluid level in the master cylinder reservoir and inspect all connections for leaks.
• Verify that the brake warning light on the instrument cluster is not illuminated.

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