Remove and replace the front brake caliper assembly on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including brake fluid system bleeding.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM or quality aftermarket (verify left/right side)
• Brake fluid copper crush washers × 2 — Use OEM specification
• Caliper slide pin boots (if damaged) × 2 — Use OEM specification
• Brake caliper grease (high-temp synthetic) × 1 — Use OEM specification

Fluids

• Mopar DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Chock rear wheels securely on both sides
3. Using turkey baster or fluid syringe, remove approximately half the brake fluid from the master cylinder reservoir to prevent overflow during caliper piston compression
4. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
5. Lift front of vehicle with floor jack at manufacturer-specified jacking point and secure with jack stands under frame rails
6. Remove wheel and tire assembly completely
7. Verify caliper side (driver or passenger) matches replacement part before beginning disassembly

Procedure

1. 1

   Clean brake caliper area
   Spray brake cleaner on caliper mounting area, slide pins, and brake line connections. Use wire brush to remove any corrosion or debris from caliper bracket bolts and slide pin areas. This prevents contamination and ensures proper torque readings during reassembly.
2. 2

   Disconnect brake hose from caliper
   Place drain pan beneath caliper. Using appropriate line wrench, loosen and remove the brake hose banjo bolt from the back of the caliper. Allow brake fluid to drain into pan. Remove and discard both copper crush washers from the banjo fitting. Immediately cap or plug the brake hose end to minimize fluid loss and prevent contamination.
   ⚠Brake fluid will drain rapidly once banjo bolt is loosened. Position drain pan carefully to catch all fluid.
3. 3

   Remove caliper slide bolts
   Locate the two caliper slide bolts (guide pins) on the rear of the caliper assembly. These are typically 18mm bolts with rubber boots. Remove both caliper slide bolts completely. Inspect the rubber boots for tears or damage; replace if compromised. On Ram 2500, these bolts thread into the caliper bracket and allow the caliper to slide for pad wear.
   ℹ️Do not confuse caliper slide bolts with caliper bracket mounting bolts. Slide bolts are accessible from the rear without removing the rotor.
4. 4

   Remove caliper from bracket
   With slide bolts removed, carefully lift and rotate the caliper away from the brake rotor and bracket. The caliper should slide off the brake pads. If caliper is seized, do not force it; check that both slide bolts are fully removed. Once free, support the caliper weight to prevent stress on the brake hose if not yet disconnected.
5. 5

   Remove brake pads and hardware (if reusing bracket)
   If only replacing the caliper and reusing the existing bracket, remove the brake pads and any anti-rattle clips or shims from the caliper bracket. Inspect the bracket slide surfaces for wear or damage. Clean the bracket mounting surfaces thoroughly with brake cleaner. If replacing the entire caliper assembly with bracket, skip to removing bracket bolts.
6. 6

   Remove caliper bracket (if replacing)
   If replacing the complete caliper assembly including bracket, locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle. These are typically larger diameter bolts requiring significant torque. Remove both bracket bolts and remove the bracket from the knuckle. Clean the mounting surfaces on the knuckle with a wire brush.
   ℹ️Caliper bracket bolts are high-torque fasteners. Use appropriate size breaker bar if necessary for removal.
   Torque spec

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

   Inspect and prepare mounting surfaces
   Thoroughly clean the caliper bracket mounting surface on the steering knuckle with wire brush and brake cleaner. Inspect slide pin bores in bracket for corrosion or damage. Clean slide pin bolts and apply thin coating of high-temperature brake caliper grease to slide pin shafts and inside slide pin boots. Verify new caliper matches the old unit exactly in configuration and brake line port location.
8. 8

   Install caliper bracket to knuckle
   Position the new or existing caliper bracket onto the steering knuckle, aligning mounting bolt holes. Apply threadlocker to bracket mounting bolt threads as specified. Thread both caliper bracket bolts by hand first to ensure proper thread engagement, then torque to specification in a cross pattern. Verify bracket is seated flush against knuckle.
   ⚠Threadlocker is recommended on caliper bracket bolts. Verify specification in service manual for correct type.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
9. 9

   Compress caliper piston
   Before installing new caliper, the piston must be fully retracted into the caliper bore. Use C-clamp or caliper piston tool to slowly compress the piston completely into the caliper housing. This creates clearance for installation over the brake pads and rotor. Monitor the master cylinder reservoir during compression to ensure it does not overflow.
   ⚠Compress piston slowly to avoid damaging internal caliper seals. Do not use excessive force.
10. 10

    Install brake pads and hardware
    Install brake pad hardware clips and anti-rattle springs into the caliper bracket per manufacturer orientation. Install inner and outer brake pads into bracket, ensuring pad backing plates are properly seated in the clips. Apply thin layer of brake caliper grease to pad ears where they contact the bracket, but keep grease away from friction material.
11. 11

    Install caliper onto bracket
    Position the new caliper over the brake pads and rotor, aligning the caliper mounting holes with the slide pin bores in the bracket. Verify the brake hose port is accessible and positioned correctly. Apply a thin coating of brake caliper grease to the slide pin bolt threads and rubber contact areas. Install both slide pin bolts and torque to specification.
    ⚠Ensure slide pin boots seat properly during bolt installation. Torn boots will allow moisture and debris to cause caliper seizure.
12. 12

    Connect brake hose with new washers
    Install NEW copper crush washers on both sides of the brake hose banjo fitting. Position the banjo fitting into the caliper inlet port, ensuring proper orientation and no twisting of the brake hose. Thread the banjo bolt by hand to ensure proper thread engagement, then torque to specification. Verify brake hose is not twisted or kinked and has adequate clearance throughout steering range.
    ⚠️CRITICAL: Always use new copper crush washers. Reusing old washers will cause brake fluid leaks and brake system failure.
    ⚠Turn steering wheel full lock left and right after installation to verify brake hose clearance. Hose must not contact suspension or steering components.
13. 13

    Bleed brake caliper
    Attach clear hose to bleeder screw and place other end in catch container. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw 1/4 turn and allow fluid and air to evacuate into container. Close bleeder screw before pedal reaches floor. Repeat process until clear, bubble-free brake fluid flows from bleeder. Torque bleeder screw to specification. Do not overtighten as bleeder valve is easily damaged.
    ⚠️CRITICAL: Never allow brake pedal to go to floor with bleeder open, as this can damage the master cylinder. Close bleeder before pedal bottoms out.
    ⚠Bleeder screw is extremely fragile. Torque carefully to specification and do not overtighten.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
14. 14

    Top off brake fluid and check system
    Fill master cylinder reservoir to MAX line with fresh Mopar DOT 4 brake fluid from sealed container. Check all brake line connections for leaks. Pump brake pedal multiple times to build pressure and verify firm pedal feel. If pedal feels soft or spongy, repeat bleeding procedure. Check brake fluid level again and top off if necessary.
    ⚠️Do not operate vehicle until firm brake pedal is achieved. Soft or spongy pedal indicates air in system or component failure.
15. 15

    Reinstall wheel and perform final checks
    Clean wheel mounting surface on hub. Install wheel and tire assembly, threading lug nuts by hand first. Tighten lug nuts in star pattern to prevent hub distortion. Lower vehicle partially so weight is on tire but jack stand is still supporting, then torque lug nuts to specification in star pattern. Remove jack stands and lower vehicle completely. Re-torque lug nuts after vehicle is on ground.
    ⚠Always torque lug nuts in proper star pattern sequence to prevent wheel and brake rotor warping.

Reassembly

1. Torque all fasteners to exact specifications provided using calibrated torque wrench
2. Always use new copper crush washers on brake line banjo fittings - never reuse
3. Verify all brake line connections are tight and free from leaks before test drive
4. Ensure slide pin boots are properly seated and not torn or damaged
5. Apply threadlocker to caliper bracket mounting bolts as specified

Verification

• With engine running, pump brake pedal several times - pedal should feel firm and not sink to floor
• Check master cylinder reservoir level - should be at MAX line with no fluid loss
• Visually inspect all brake connections for fluid leaks, particularly at banjo bolt and bleeder screw
• Perform low-speed test in safe area - brake application should be smooth with no pulling to either side
• After initial test drive, recheck all fastener torques and brake fluid level
• Check for proper brake hose clearance by turning steering wheel full lock in both directions with vehicle stationary
• Verify no brake warning lights are illuminated on instrument cluster
• Road test vehicle at various speeds, verifying proper brake operation and firm pedal feel before returning to service
• Be aware that new brake pads require 200-300 miles of gentle bedding-in period for optimal performance

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