Brake Caliper Bracket

This procedure covers the removal and replacement of the brake caliper bracket on a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD. This is a safety-critical brake system repair requiring precise reassembly and thorough verification.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM specification or equivalent matching front/rear position
• Copper brake line crush washers × 2 — If disconnecting brake line
• Caliper slide pins and boots × 1 — Inspect and replace if damaged

Fluids

• DOT 3 brake fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and place transmission in Park (automatic) or 1st gear (manual)
2. Apply parking brake if working on front brakes only. If working on rear brakes, chock front wheels securely
3. Loosen wheel lug nuts 1/4 turn while vehicle is on the ground
4. Lift vehicle using floor jack at appropriate frame jacking point
5. Support vehicle securely with jack stands on solid frame contact points - never rely on jack alone
6. Remove wheel completely and set aside
7. Verify vehicle is stable by gently attempting to rock it before working underneath
8. Open brake fluid reservoir cap to allow fluid to return when compressing caliper (if needed)
9. Have catch pan positioned under brake assembly to capture any fluid spillage

Procedure

1. 1

   Remove brake caliper from bracket
   Using the correct socket (verify size for this vehicle), remove the two caliper slide bolts that secure the caliper to the bracket. These are typically located on the back side of the caliper. Once removed, carefully lift the caliper off the brake rotor and brake pads. Do NOT let the caliper hang by the brake hose - use mechanics wire or a caliper hanger to suspend it from the suspension or frame. Do not disconnect the brake line at this point unless the caliper is also being replaced.
   ⚠Never allow the brake caliper to hang by its brake hose. The weight can damage the hose internally, leading to brake failure.
2. 2

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket. Note the position and orientation of any anti-rattle clips, shims, or pad hardware for reinstallation. Remove any pad retaining clips or springs from the bracket. Keep track of all hardware - take photos if necessary for reference during reassembly.
3. 3

   Disconnect brake line if necessary
   If the caliper bracket damage or replacement requires caliper removal, use the appropriately sized wrench to remove the banjo bolt securing the brake hose to the caliper (verify the exact size for this vehicle). Hold the caliper connection stationary while turning the line fitting to prevent damage. Allow brake fluid to drain into catch pan. Immediately plug or cap the brake line and caliper opening to prevent fluid loss and contamination entry. Note: If bracket can be removed without caliper removal, skip this step to avoid bleeding.
   ⚠Brake fluid will drain from the disconnected line. Have catch pan ready and be prepared to plug openings immediately.
4. 4

   Remove caliper bracket mounting bolts
   Locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle (front) or axle housing (rear). These bolts are large and torqued very tightly - verify the exact size and torque specification for this specific vehicle from a factory service manual before reassembly. Apply penetrating oil and let soak for 10-15 minutes if bolts show corrosion. Use a breaker bar or impact wrench to remove these bolts. The bracket may be tight against the hub - carefully pry or tap to break it free if necessary.
   ⚠Caliper bracket bolts are extremely tight and may require significant force. Ensure tools are properly seated to avoid rounding bolt heads. Use impact-rated sockets if using an impact wrench.
5. 5

   Remove caliper bracket and inspect mounting surfaces
   Remove the caliper bracket completely from the vehicle. Inspect the mounting surface on the knuckle or axle for damage, corrosion, or debris. Clean mounting surfaces thoroughly with a wire brush and brake cleaner. Inspect the caliper bracket bolt threads in the knuckle - if damaged, the knuckle may require thread repair or replacement before proceeding.
6. 6

   Prepare new caliper bracket
   Clean the new caliper bracket with brake cleaner. Inspect all sliding surfaces and hardware mounting points. Clean the caliper bracket bolt threads with a wire brush. Apply a thin coat of anti-seize compound to the bolt threads (not the seating surface) if desired, though some manufacturers do not recommend this for critical torque-to-yield applications. Verify the new bracket matches the old bracket exactly in design and mounting hole positions.
7. 7

   Install new caliper bracket
   Position the new caliper bracket onto the steering knuckle or axle housing, aligning the mounting bolt holes. Start both caliper bracket bolts by hand to ensure proper thread engagement. Once both bolts are hand-started, use a torque wrench to tighten them to the manufacturer's specified torque in a cross pattern (alternate between bolts). CRITICAL: You must obtain the correct torque specification from a factory service manual or dealer - typical values are 130-180 ft-lbs but this MUST be verified for this specific vehicle.
   ⚠️Caliper bracket bolts MUST be torqued to exact specification. Under-torquing can allow the bracket to loosen, causing catastrophic brake failure. Over-torquing can strip threads or break bolts. Obtain correct specification before proceeding.
8. 8

   Reinstall brake pads and hardware
   Clean the brake pad sliding surfaces on the bracket with brake cleaner. Install any anti-rattle clips, shims, or springs in their original positions. Apply a thin film of brake caliper grease (high-temperature silicone brake lubricant) to the pad backing plate contact points on the bracket - do NOT get grease on pad friction material or rotor. Install brake pads in the correct orientation, ensuring they slide freely in the bracket.
9. 9

   Reinstall brake caliper
   If caliper was removed from brake line, reconnect the brake line to the caliper using NEW copper crush washers. Tighten the brake line fitting to specification (typically 10-15 ft-lbs - verify specification). Remove the caliper from its support wire/hanger. Inspect caliper slide pins for damage or dried grease - clean and lubricate with silicone brake grease if necessary. Position the caliper over the brake pads and bracket. Install and tighten the caliper slide bolts to the manufacturer's specified torque - verify the exact specification for this specific vehicle before final tightening.
10. 10

    Bleed brake system
    If the brake line was disconnected, the brake system MUST be bled to remove air. Attach clear tubing to the bleeder valve and submerge the other end in a container of clean brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder valve 1/4 turn - fluid and air will exit. Close the bleeder before the pedal reaches the floor. Repeat until no air bubbles appear in the tubing. Check and refill brake fluid reservoir frequently - never let it run dry or you will introduce more air. Bleed all four wheels if the system was opened significantly or if pedal feel is soft.
    ⚠️Air in the brake system will cause spongy pedal feel and reduced braking effectiveness, potentially causing an accident. The system MUST be properly bled if any brake line connections were opened.
11. 11

    Reinstall wheel and lower vehicle
    Clean the wheel hub surface and wheel mounting surface with a wire brush. Install the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground but doesn't bear full weight. Torque the lug nuts to the manufacturer's specification (verify exact value for this vehicle; heavy-duty 3500 trucks often require higher torque, and dual-rear-wheel models may have a specific spec) in a star pattern. Fully lower the vehicle and remove jack stands and jack.

Reassembly

1. Ensure all caliper bracket bolts are torqued to the exact manufacturer specification using a calibrated torque wrench
2. Verify caliper slide bolts are properly torqued and that the caliper can slide freely on its pins
3. Refill brake fluid reservoir to the MAX line with fresh DOT 3 brake fluid from a sealed container
4. Securely tighten the brake fluid reservoir cap
5. Double-check that no tools or parts are left in the wheel well or under the vehicle
6. Verify the wheel lug nuts are properly torqued after the vehicle is lowered

Verification

• CRITICAL: Before moving the vehicle, pump the brake pedal several times until it feels firm and holds pressure. If the pedal sinks to the floor, DO NOT drive the vehicle - there is air in the system or a leak.
• Check brake fluid level in the reservoir - should be at MAX line. Add DOT 3 brake fluid if necessary.
• Visually inspect around the caliper bracket, caliper, and brake line connections for any signs of brake fluid leakage.
• Start the engine (to activate the brake booster) and hold firm pressure on the brake pedal for 30 seconds. The pedal should remain firm and not sink. If it sinks, there is a leak or air in the system.
• Perform a low-speed test drive in a safe area (empty parking lot). Test brakes at 5-10 mph to verify proper operation before entering traffic.
• During test drive, verify the vehicle brakes smoothly without pulling to one side. Any pulling indicates uneven brake operation or possible air in one circuit.
• Listen for any unusual noises (grinding, squealing, rubbing) that could indicate improper installation.
• After test drive, re-check all mounting bolts and lug nuts for proper torque.
• Re-check brake fluid level after test drive and top off if necessary.
• If you experience ANY abnormal brake behavior (soft pedal, pulling, noise, vibration), DO NOT drive the vehicle. Have it inspected by a qualified technician immediately.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle