Parking Brake Actuator

Remove and replace the parking brake actuator assembly on a 2005 Dodge Viper, including brake fluid bleeding and system verification.

Warnings

Tools required

Parts

• Parking brake actuator assembly × 1 — Use OEM specification
• Brake fluid (DOT 4) × 1 — Mopar or equivalent DOT 4

Fluids

• DOT 4 brake fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake (if functional).
2. Place wheel chocks in front of both front wheels.
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground.
4. Raise rear of vehicle with floor jack at designated lift points and secure with jack stands rated for vehicle weight.
5. Remove both rear wheels completely and set aside.
6. Verify vehicle stability by gently pushing on rear bumper before working underneath.
7. Open brake fluid reservoir cap slightly to relieve pressure and facilitate brake line disconnection.
8. Have brake fluid catch container and rags ready to capture spilled fluid.

Procedure

1. 1

   Access and identify parking brake actuator
   Locate the parking brake actuator on the rear brake caliper assembly. The actuator is typically mounted to the inboard side of the caliper with a cable connection running to the parking brake lever mechanism. Use an inspection mirror and shop light to identify the actuator mounting bolts and cable connection point. Note the routing of the parking brake cable for reinstallation.
2. 2

   Disconnect parking brake cable
   Release tension on the parking brake cable by having an assistant release the parking brake lever inside the vehicle (or use the manual release mechanism if the system is non-functional). Disconnect the parking brake cable from the actuator lever arm. This typically involves removing a retaining clip or cotter pin with needle-nose pliers, then sliding the cable end out of the lever slot. Support the cable to prevent it from retracting into the vehicle.
3. 3

   Disconnect brake hydraulic line
   Position the brake fluid catch container beneath the actuator. Using a flare nut wrench or appropriate wrench, carefully loosen the brake line fitting that connects to the actuator. The Viper uses a specific brake line routing - do NOT disconnect lines at the caliper body unless you are also replacing the caliper. Disconnect only the line running to the actuator assembly itself. Allow brake fluid to drain into the catch container. Cap or plug the open line immediately to prevent contamination.
   ⚠Brake fluid will begin draining immediately upon loosening the fitting. Have the catch container positioned before breaking the seal.
4. 4

   Remove actuator mounting fasteners
   Locate the 2 bolts securing the parking brake actuator to the rear caliper housing. These are typically located on the inboard side of the caliper assembly. Using the appropriate socket (likely 10mm or 13mm), remove these mounting bolts completely. Keep track of any washers or spacers that may be present.
5. 5

   Remove old actuator assembly
   Carefully separate the parking brake actuator from the caliper housing. The actuator may have an O-ring or gasket seal at the interface - note its condition and position. If the actuator is seized or corroded to the caliper body, gently tap with a soft mallet to break the seal. Do not pry against machined caliper surfaces. Inspect the mounting surface on the caliper for corrosion, damage, or debris.
   ⚠Do not damage the caliper housing mounting surface. Any scoring or damage may prevent proper sealing and cause brake fluid leaks.
6. 6

   Prepare mounting surface and new actuator
   Clean the actuator mounting surface on the caliper housing using a wire brush or contact cleaner. Remove all corrosion, old gasket material, and debris. Inspect the surface for damage. Verify the new parking brake actuator matches the original unit in mounting hole pattern, cable connection point, and hydraulic port location. Install a new O-ring or gasket onto the new actuator if one is provided in the replacement kit. Lightly lubricate the O-ring with clean brake fluid (not petroleum-based lubricant).
7. 7

   Install new actuator assembly
   Position the new parking brake actuator onto the caliper housing, aligning the mounting holes and ensuring the O-ring or gasket is properly seated. The hydraulic port should align with the brake line connection point. Hand-start both mounting bolts to ensure proper thread engagement before tightening. Tighten the mounting bolts to 27 Nm (20 lb-ft) using a torque wrench in a cross pattern to ensure even seating.
   Torque spec

   Caliper Mounting Bolts88 Nm (65 lb-ft)
8. 8

   Reconnect brake hydraulic line
   Remove the cap or plug from the brake line. Inspect the line fitting threads and flare seat for damage - replace the line if threads are stripped or the flare is damaged. Thread the brake line fitting into the new actuator by hand first to ensure proper thread engagement and prevent cross-threading. Once hand-tight, use a flare nut wrench to snug the fitting. Torque to the appropriate specification for brake line fittings (typically 12-15 Nm, but verify for this platform). Do not overtighten as this can damage the flare seat.
   ⚠Cross-threading brake line fittings is a common cause of brake fluid leaks. Always start fittings by hand and verify smooth thread engagement.
9. 9

   Reconnect parking brake cable
   Route the parking brake cable to the actuator lever arm following the original path noted during disassembly. Insert the cable end into the lever slot and secure with the retaining clip or new cotter pin. Ensure the cable moves freely without binding and that the lever arm returns to its rest position when released. Verify adequate cable slack exists to prevent binding during wheel travel.
10. 10

    Bleed parking brake hydraulic circuit
    Refill the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid. Locate the bleeder screw on the parking brake actuator assembly. Attach a clear tube to the bleeder screw and route the other end into a catch container. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/4 turn using a bleeder wrench while the pedal is held down. Observe fluid and air bubbles flowing through the clear tube. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the fluid stream and the brake pedal feels firm. Torque the bleeder screw to 10 Nm (7 lb-ft) when bleeding is complete. Top off the reservoir as needed during the bleeding process.
    ⚠️Never allow the brake fluid reservoir to run empty during bleeding. This will introduce air into the entire brake system and require bleeding all four corners.
    ⚠The bleeder screw is brass and easily damaged. Do not overtighten beyond the specified 10 Nm (7 lb-ft) torque.
11. 11

    Repeat for opposite side if necessary
    If replacing both rear parking brake actuators, repeat steps 1-10 for the opposite rear wheel assembly. Bleed both sides thoroughly to ensure all air is removed from the system.
12. 12

    Reinstall rear wheels
    Clean the wheel mounting surfaces on the hubs to remove any rust or debris. Position the rear wheels onto the hubs and hand-start all lug nuts. Tighten the lug nuts in a star pattern to the factory-specified torque (verify against the 2005 Viper service manual, approximately 135 Nm / 100 lb-ft) using a torque wrench. Lower the vehicle partially so the wheels contact the ground but the suspension is not fully loaded, then perform a final torque check in the star pattern.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)

Reassembly

1. Verify all brake line fittings are tight and show no signs of leakage.
2. Ensure parking brake cable is properly routed and secured with no interference points.
3. Top off brake fluid reservoir to MAX line with fresh DOT 4 fluid.
4. Securely tighten the brake fluid reservoir cap.

Verification

• With the vehicle still on jack stands and wheels reinstalled, start the engine and pump the brake pedal. The pedal should feel firm within 3-4 pumps and hold steady pressure without sinking.
• Inspect all brake line connections at the new actuator for any signs of fluid leakage. Look for wet spots or drips.
• Pull the parking brake lever inside the vehicle and verify it engages with normal lever travel (typically 4-8 clicks). The rear wheels should resist rotation when parking brake is engaged.
• Release the parking brake and verify the rear wheels rotate freely with no binding or dragging.
• Lower the vehicle to the ground and torque lug nuts one final time in a star pattern to 140 Nm (103 lb-ft).
• Test drive the vehicle in a safe area at low speed (under 10 mph). Apply the service brakes firmly and verify the pedal feels normal with no sponginess. Test the parking brake on a slight incline to verify it holds the vehicle in place.
• After test drive, re-inspect all connections for leaks and re-check brake fluid level. Add fluid if needed.
• If the brake pedal feels spongy or the parking brake does not hold, do NOT drive the vehicle. Re-bleed the system or seek professional assistance.

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