Brake Caliper - Front

Complete removal and installation of the front brake caliper on a 2005 Dodge Viper, including brake line disconnection, caliper bracket removal, and system bleeding.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM specification or aftermarket equivalent
• Brake line copper crush washers × 2 — Use OEM specification - 2 per banjo bolt
• Brake fluid DOT 4 × 1 — 1 qt minimum for bleeding

Fluids

• DOT 4 brake fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly.
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on the ground.
3. Raise front of vehicle with floor jack at designated front jacking point and support securely on jack stands rated for at least 3,500 lbs at the frame rails.
4. Remove front wheel completely and set aside.
5. Open brake fluid reservoir cap slightly to allow fluid to compress back when retracting piston (if reusing old caliper).
6. Place brake fluid catch pan under the caliper work area.
7. Verify brake components are cool to the touch before beginning work.

Procedure

1. 1

   Disconnect Brake Line from Caliper
   Locate the brake line banjo bolt on the caliper body. Using the correctly sized wrench (verify size against OEM documentation), loosen and remove the banjo bolt while supporting the brake line to prevent twisting. Allow brake fluid to drain into the catch pan. Remove and discard both copper crush washers (one on each side of the banjo fitting). Immediately plug the brake line end with a clean rubber cap or wrap with clean plastic to prevent contamination and further fluid loss.
2. 2

   Remove Caliper Mounting Bolts
   The 2005 Viper uses a fixed opposed-piston Brembo caliper mounted directly to the knuckle (no slide pins). Identify the caliper mounting bolts securing the caliper to the knuckle/bracket. Remove both mounting bolts completely. Verify the exact bolt head size against OEM documentation before selecting a socket.
3. 3

   Remove Caliper from Bracket
   Carefully lift the caliper assembly off the brake rotor and away from the mounting bracket. The caliper should come free easily once the mounting bolts are removed. If resistance is felt, verify both mounting bolts are fully removed and that the brake pads are not seized in the bracket. Set the old caliper aside for core return if applicable.
4. 4

   Remove Caliper Bracket
   The 2005 Viper's fixed Brembo caliper typically mounts directly to the knuckle without a separate removable caliper bracket. If no bolt-on bracket is present, skip this step. If a bracket/adapter is present, confirm bolt head size and torque against OEM documentation before removal, applying penetrating oil to any corroded fasteners. knuckle for corrosion or damage.
5. 5

   Inspect Brake System Components
   With the caliper and bracket removed, inspect the brake rotor surface for scoring, cracks, or excessive wear. Measure rotor thickness if gauge is available and compare to minimum specification (typically stamped on rotor hat). Inspect the brake pads (if reusing bracket) for uneven wear patterns. Check the caliper mounting surfaces on the knuckle for corrosion, cracks, or damage. Clean mounting surfaces with a wire brush if surface rust is present.
6. 6

   Prepare New Caliper
   Unbox the new brake caliper and verify it matches the old unit in mounting configuration and brake line position (driver vs passenger side specific). If the caliper includes a bleeder screw cap, leave it in place until bleeding. Verify the caliper piston is fully retracted. If not, carefully compress the piston using a C-clamp or brake piston tool - place a clean rag over the piston to protect it. Remove any protective caps from the brake line inlet port.
7. 7

   Install Caliper Bracket
   Position the caliper bracket onto the steering knuckle, aligning the mounting holes. Apply a small amount of medium-strength threadlocker to the bracket bolt threads if desired (wipe away excess). Insert both bracket bolts and hand-thread them to prevent cross-threading. Using a torque wrench and the correct socket, tighten the caliper (or bracket) mounting bolts to the OEM-specified torque in a cross-pattern. Verify the exact torque value and socket size against 2005 Viper service documentation before final tightening.
   Torque spec

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

   Install Brake Pads
   If brake pads were removed or if installing new pads with the new caliper, install them now into the caliper bracket. Apply a thin coat of high-temperature brake lubricant to the pad backing plate ears (not the friction surface). Ensure pads are properly seated in the bracket with anti-rattle clips correctly positioned if equipped. Verify pads can move freely in the bracket without binding.
9. 9

   Mount New Caliper
   Position the new caliper over the brake rotor and align it with the mounting bracket. Ensure the brake pads are properly positioned on each side of the rotor. Insert the caliper mounting bolts through the caliper and into the bracket or slide pins. Hand-thread both bolts to prevent cross-threading, then tighten securely. Torque the caliper mounting bolts to the OEM-specified value for the 2005 Viper fixed Brembo caliper. Do not substitute hand-tightening for a torque specification on this safety-critical fastener — obtain the exact torque from OEM service documentation before final assembly.
   ℹ️Verify caliper slides freely on the mounting pins before final tightening to ensure even pad wear.
10. 10

    Connect Brake Line
    Remove the protective cap or plastic from the brake line. Install one NEW copper crush washer onto the banjo bolt, insert the banjo fitting into the caliper inlet port, place the second NEW copper crush washer on top, and hand-thread the banjo bolt. Using the correctly sized wrench and a torque wrench, tighten the banjo bolt to the OEM-specified torque. Confirm the exact torque value and wrench size against 2005 Viper service documentation. Do not overtighten as this can damage the caliper body or cause leaks.
    ⚠️Reusing old copper washers will likely result in brake fluid leakage and brake system failure. Always use new washers.
    Torque spec

    Brake Line Banjo Bolt25 Nm (18 lb-ft)
11. 11

    Bleed Brake Caliper
    Locate the bleeder screw on the top rear of the new caliper. Place a clear tube over the bleeder nipple with the other end submerged in clean DOT 4 brake fluid in a container. Have an assistant pump the brake pedal 3-4 times and hold pressure. Using a 10mm wrench or bleeder wrench, open the bleeder screw 1/4 turn. Fluid and air will escape. Close the bleeder before the pedal reaches the floor. Repeat this process until no air bubbles appear in the tube and only clean fluid flows. Tighten the bleeder screw to 10 Nm (7 lb-ft) when complete. Check brake fluid reservoir level frequently during bleeding and top off as needed - never let it run dry. Note: Never allow the brake fluid reservoir to empty during bleeding, as this will introduce air into the system and complicate bleeding. Note that the 2005 Viper did not come equipped with ABS; verify system configuration before assuming scan-tool bleeding is required.
    ⚠️Never allow the brake fluid reservoir to empty during bleeding. This will introduce air into the ABS module, requiring professional scan tool bleeding.
    Torque spec

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

    Reinstall Wheel
    Position the wheel onto the hub and hand-thread all lug nuts to prevent cross-threading. Tighten lug nuts in a star pattern until snug but do not fully torque while vehicle is on jack stands. Lower the vehicle from jack stands to the ground using the floor jack. With full vehicle weight on the wheel, torque lug nuts to the OEM-specified value for the 2005 Viper in a star pattern using a torque wrench. Verify the exact lug nut torque against OEM documentation before finalizing.
13. 13

    Final System Bleeding and Testing
    With the vehicle still parked, pump the brake pedal slowly 10-15 times to seat the caliper piston against the pads. The pedal should become firm. If the pedal remains soft or goes to the floor, repeat bleeding procedure on the affected caliper. Check all connections for leaks, especially the banjo bolt fitting. Inspect under the vehicle for any dripping brake fluid. Top off the brake fluid reservoir to the MAX line with fresh DOT 4 fluid and securely reinstall the reservoir cap.

Reassembly

1. Reassembly is covered in the installation steps above - ensure all torque specifications are followed exactly.
2. If replacing calipers on both sides, repeat the entire procedure for the opposite side.
3. Consider replacing brake fluid entirely if it appears dark or contaminated - brake fluid absorbs moisture over time and degrades.
4. After any brake work, clean wheel faces and caliper exterior of any brake fluid residue to prevent paint damage.

Verification

• With engine off, pump brake pedal firmly 15-20 times. Pedal should become firm and hold pressure without slowly sinking.
• Visually inspect the banjo bolt connection and bleeder screw for any signs of brake fluid leakage.
• Start the engine and verify the brake warning light is not illuminated on the dashboard.
• Perform a low-speed brake test in a safe area (parking lot or driveway at 5-10 mph). Brakes should engage smoothly without pulling to one side.
• Perform a controlled stop from 25-30 mph in a safe area with no traffic. Braking should be firm, even, and without vibration or pulling.
• Check brake pedal feel - it should be firm and consistent, requiring moderate pressure for full braking.
• After test drive, re-inspect all connections for leaks while brakes are warm.
• Re-torque wheel lug nuts after 50-100 miles of driving to ensure they remain properly seated.

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