This procedure covers removal and replacement of a single front brake rotor on a 2014 Ram 2500 with the 6.7L Cummins diesel engine, including caliper removal, rotor replacement, and proper reassembly with critical torque specifications.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM specification or equivalent quality
• Rotor set screws (if reusing is not possible) × 2 — M6 x 1.0 Phillips head

Fluids

• Mopar DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels on opposite side of repair
3. Loosen wheel lug nuts on the front wheel to be serviced while vehicle is still on ground (do not remove)
4. Lift front of vehicle using floor jack at manufacturer's recommended lift point
5. Place jack stands under frame rails on side being serviced
6. Lower vehicle onto jack stands and verify stability before working
7. Remove wheel lug nuts completely and remove wheel
8. Clean brake assembly area with brake cleaner to remove dust and debris

Procedure

1. 1

   Compress brake caliper piston
   Before removing the caliper, compress the caliper piston slightly to make removal easier and prevent brake fluid overflow from the master cylinder reservoir. Use a C-clamp or brake caliper compression tool between the back of the caliper and the outboard brake pad. Compress slowly and smoothly. If the brake fluid reservoir is very full, remove some fluid with a turkey baster or fluid transfer pump to prevent overflow.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear side of the caliper assembly. These are hex head bolts. Using the appropriate hex socket, remove both caliper slide pin bolts. Keep these bolts as they will be reused. The caliper will now be free to pivot away from the rotor.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove and support brake caliper
   Carefully pivot the caliper upward and away from the rotor. Do NOT let the caliper hang by the brake hose. Use wire, a bungee cord, or a suitable hook to suspend the caliper from the suspension component or frame. Ensure there is no tension or stress on the brake hose. Inspect the brake hose for any cracks, swelling, or damage while accessible.
   ⚠️Allowing the caliper to hang by the brake hose can damage the hose internally, leading to brake failure.
4. 4

   Remove caliper bracket
   The caliper bracket is mounted to the steering knuckle with two large bolts. These are high-torque fasteners. Use a breaker bar and appropriate socket to remove both caliper bracket bolts. Note: On some 2014 Ram 2500 models, there may be variation in bracket bolt size. The bolts you remove will determine which torque specification to use on reassembly (101 lb-ft or 88 lb-ft). Keep these bolts organized for reinstallation. Remove the caliper bracket completely.
   Torque spec

   Caliper Bracket Bolts137 Nm (101 lb-ft)
5. 5

   Remove brake pads and hardware
   With the bracket removed, the brake pads and any anti-rattle clips or shims can now be removed if not already detached. Keep track of the orientation and position of all hardware components, taking photos if necessary. These will be reinstalled in the same configuration. Inspect brake pads for wear, contamination, or damage.
6. 6

   Remove rotor set screws
   Locate the rotor set screws (typically 1-2 Phillips head screws) securing the rotor to the hub. These screws often corrode and may be difficult to remove. Use a Phillips screwdriver or impact driver. Apply penetrating oil if necessary and let sit for several minutes. If screws are severely corroded, they may need to be drilled out. These screws are for assembly purposes only and can be replaced or omitted on reassembly (though reinstallation is recommended).
   Torque spec

   Rotor Set Screws9 Nm (7 lb-ft)
7. 7

   Remove old brake rotor
   Pull the rotor straight off the wheel hub. If the rotor is stuck due to corrosion, use a rubber mallet to tap around the rotor face or on the mounting surface from behind (not on the friction surface). Do not hit the rotor friction surface with a metal hammer. If severely seized, use a penetrating lubricant at the hub-rotor interface and allow time to soak. Some rotors have threaded holes for a puller tool if necessary.
8. 8

   Clean hub mounting surface
   With the rotor removed, thoroughly clean the wheel hub mounting surface with a wire brush and brake cleaner. Remove all rust, scale, and debris. The mounting surface must be clean and smooth to ensure proper rotor seating and prevent runout. Apply a thin layer of anti-seize compound to the hub mounting surface to prevent future corrosion and facilitate easier removal next time. Do not get anti-seize on wheel studs or rotor friction surfaces.
9. 9

   Install new brake rotor
   Clean the new rotor thoroughly with brake cleaner on both sides to remove protective coating and any manufacturing oils. Wipe dry with a clean, lint-free cloth. Slide the new rotor onto the wheel hub, aligning any indexing features or holes. Ensure the rotor sits flush against the hub mounting surface with no gaps or misalignment. Install rotor set screws (if using) and tighten to specification to hold rotor in place during assembly.
   ⚠Failure to clean protective coating from new rotors will cause brake noise, reduced braking performance, and accelerated pad wear.
   Torque spec

   Rotor Set Screws9 Nm (7 lb-ft)
10. 10

    Reinstall brake pads and hardware
    Reinstall brake pad hardware, anti-rattle clips, and shims in their original positions. Install the inner and outer brake pads. If pads are being reused, ensure they are installed in the same position they were removed from (left/right orientation matters).
11. 11

    Reinstall caliper bracket
    Position the caliper bracket back onto the steering knuckle. Install both caliper bracket bolts and hand-tighten. Clean the bolt threads and apply thread-locking compound to the bolts if specified or if recommended by the service manual. Using a torque wrench, torque both caliper bracket bolts to the appropriate specification based on the bolt type identified during removal (88 lb-ft for front-specific bolts or 101 lb-ft for standard bracket bolts).
    ⚠️Improperly torqued caliper bracket bolts can cause caliper detachment and complete brake failure. Always use a calibrated torque wrench.
    Torque spec

    Caliper Bracket Bolts137 Nm (101 lb-ft)
12. 12

    Prepare and reinstall brake caliper
    Clean the caliper slide pin bolts and inspect them for wear or damage. Apply fresh silicone brake grease to the slide pin bolt shafts (not to the threads). Remove the caliper from its temporary support. Position the caliper over the brake pads and rotor, ensuring proper alignment. Install both caliper slide pin bolts and hand-tighten. Using a torque wrench, torque both slide pin bolts to specification (26 lb-ft).
    ⚠Over-torquing slide pin bolts can cause binding and uneven pad wear. Under-torquing can allow caliper movement and noise.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Reinstall wheel
    Clean the wheel mounting surface on the rotor hat. Place the wheel onto the hub and install all lug nuts by hand. Tighten lug nuts in a star/cross pattern to draw the wheel evenly onto the hub. Do NOT fully torque at this stage. Raise the vehicle slightly to remove weight from the jack stands, remove the jack stands, and carefully lower the vehicle to the ground.
14. 14

    Torque wheel lug nuts
    With the vehicle on the ground and full weight on the wheel, torque all lug nuts to specification (103 lb-ft) using a star/cross pattern. Start at one lug nut, move to the opposite side, then continue in a star pattern until all are torqued. Re-check each lug nut in the same pattern to ensure proper torque.
    ⚠️Improperly torqued lug nuts can cause wheel detachment while driving. Always torque in a star pattern with a calibrated torque wrench.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
15. 15

    Bed brake pads and verify operation
    Before driving, pump the brake pedal several times to reseat the caliper piston against the new rotor. The pedal should feel firm. Check the brake fluid level in the master cylinder reservoir and top off with Mopar DOT 4 brake fluid if necessary. Perform initial test stops at low speed in a safe area to verify proper brake operation. Perform a proper brake pad bedding procedure: make 10-15 moderate stops from 40 mph with 30-second cooling intervals between stops. Avoid hard braking for the first 200-300 miles to allow proper pad-rotor mating.
    ⚠️Before driving, the brake pedal MUST feel firm after pumping. A soft or spongy pedal indicates air in the system or incorrect assembly. Do not drive until corrected.

Reassembly

1. All fasteners must be torqued to specification using a calibrated torque wrench
2. Silicone brake grease must be applied to caliper slide pin bolts before installation
3. Anti-seize compound should be applied to hub mounting surface to prevent future corrosion
4. New rotors must be thoroughly cleaned with brake cleaner before installation to remove protective coating
5. Wheel lug nuts must be torqued in a star pattern with vehicle weight on the ground

Verification

• Pump brake pedal until firm before starting vehicle or attempting to drive
• Check brake fluid level in master cylinder reservoir and top off if necessary with Mopar DOT 4 brake fluid
• Verify no brake fluid leaks at caliper or connections
• Test brakes at low speed in a safe area before normal driving
• Verify no unusual noises, vibrations, or pulling during braking
• After 50-100 miles, re-torque wheel lug nuts to specification
• Verify caliper slide pin bolts and bracket bolts remain tight after initial test drive
• Confirm brake pedal feel remains firm and consistent with no fade or sponginess
• If any grinding, squealing, pulling, or pedal softness occurs, immediately inspect the brake system and correct any issues before further driving

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