Brake Pads and Rotors - Rear

This procedure covers replacement of rear brake pads and rotors on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including caliper service and proper break-in procedure.

Warnings

Tools required

Parts

• Rear brake pad set (left and right) × 1 — OEM or equivalent for dual rear wheel application
• Rear brake rotors × 2 — Verify DRW vs SRW application
• Caliper hardware/pin kit × 1 — Includes slide pins and boots

Fluids

• DOT 3 brake fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and place wheel chocks in front of front wheels
2. Start engine and pump brake pedal several times, then turn off engine to relieve vacuum assist pressure
3. Open hood and locate brake fluid reservoir. Using turkey baster or suction tool, remove approximately 1/3 of brake fluid from reservoir to prevent overflow when compressing pistons. Dispose of old fluid properly
4. Loosen rear wheel lug nuts 1/2 turn while vehicle is on ground
5. Raise rear of vehicle with floor jack at rear axle differential and support with jack stands under frame rails behind rear axle. Ensure vehicle is stable before working underneath
6. Remove rear wheels completely and set aside

Procedure

1. 1

   Inspect brake system condition
   Before disassembly, inspect the brake system. Check brake hoses for cracks, swelling, or leaks. Inspect caliper for fluid leaks around piston boot and bleeder screw. Note the routing of any brake wear sensors if equipped. If calipers are leaking or seized, replacement is recommended before continuing.
2. 2

   Remove caliper slide pins and caliper
   Locate the two caliper slide pins on the back of the caliper. These are typically driven by a hex/Allen socket - verify the exact size on your vehicle before applying force. Remove both slide pin bolts completely. Carefully lift the caliper up and off the rotor. Do NOT let the caliper hang by the brake hose - support it with wire or a bungee cord hung from the frame or axle.
3. 3

   Remove brake pads and hardware
   Remove the old brake pads from the caliper bracket. Note the position of any anti-rattle clips, shims, or springs for reinstallation. Remove the caliper bracket by removing the two large bolts (typically 18mm) securing it to the axle housing. These bolts may require significant force and penetrating oil if corroded.
   ⚠Caliper bracket bolts are extremely tight. Ensure proper socket engagement to avoid rounding bolt heads. Use 1/2" drive tools for additional leverage.
4. 4

   Remove old rotors
   Remove the rotor from the wheel hub. On Ram 3500, rotors may be held by small retaining clips or screws - remove these first if present. If rotor is stuck due to rust, use penetrating oil around the hub contact area and tap with a rubber mallet or dead blow hammer from behind. Do not strike the rotor friction surface. If extremely stuck, and if the rotor has jacking/threaded holes on the rotor face, thread appropriately sized bolts into these holes to push it off the hub (verify thread size before use).
5. 5

   Clean and prepare hub surface
   Use a wire brush to thoroughly clean all rust and corrosion from the wheel hub face where the rotor mounts. Clean the hub pilot (center ring) that centers the rotor. Apply a thin coat of high-temperature brake grease to the hub face (not on the pilot or rotor hat). This prevents rotor-to-hub corrosion and aids future removal.
6. 6

   Install new rotors
   Spray new rotors with brake cleaner to remove protective oil coating from both friction surfaces. Allow to dry completely. Install rotor onto hub, ensuring it sits flat against the cleaned hub surface. If the rotor has directional cooling vanes, verify correct orientation (typically marked on rotor). Install any retaining clips or screws if originally equipped to hold rotor in place during assembly.
7. 7

   Prepare caliper bracket and install
   Clean the caliper bracket thoroughly with wire brush and brake cleaner, paying special attention to the pad slide surfaces where brake pads contact the bracket. Apply thin coat of high-temperature brake grease to these slide surfaces. Reinstall bracket to axle housing and tighten the two mounting bolts. Without torque specifications in database, consult the factory service manual for the exact value (rear caliper anchor/bracket bolts on this heavy-duty application are typically in the 220-250 ft-lbs range) before applying final torque.
8. 8

   Compress caliper piston
   Before installing new pads, the caliper piston must be compressed fully into the bore. Place C-clamp or brake piston tool against piston and back of caliper housing. Slowly compress piston until it is fully seated. Monitor brake fluid reservoir during this process - fluid level will rise. Remove excess fluid if necessary to prevent overflow.
   ⚠Compress piston slowly to avoid damaging caliper seal. If piston does not compress smoothly or caliper is leaking, caliper replacement is necessary.
9. 9

   Install new brake pads and hardware
   Install new hardware clips into caliper bracket if included in kit. Install inner and outer brake pads into bracket, ensuring they are seated properly in the hardware clips. Pads should slide smoothly in the bracket. Apply small amount of high-temperature brake grease to pad ears (metal tabs) where they contact bracket, but keep all grease away from friction material.
10. 10

    Service caliper slide pins and reinstall caliper
    Remove slide pins from caliper bracket. Inspect rubber boots for tears or damage - replace if compromised. Clean old grease from pins and bores. Apply fresh high-temperature brake grease to slide pins. Reinstall pins into bracket boots. Position caliper over brake pads and align with slide pin holes. Install and tighten both slide pin bolts. Without torque specs in database, consult the factory service manual for the exact guide pin bolt torque specification before final tightening.
11. 11

    Repeat for opposite side
    Perform steps 1 through 10 for the opposite rear wheel to complete both rear brakes. It is critical to replace both sides together to maintain balanced braking performance.
12. 12

    Reinstall wheels and restore brake pedal
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground and torque lug nuts to specification in star pattern (approximately 145 ft-lbs for Ram 3500, but verify the exact value for your SRW or DRW configuration in the owner's manual). Before moving vehicle, pump brake pedal slowly until pedal becomes firm - this repositions caliper pistons against new pads. Pedal should become firm within 5-10 pumps. Check brake fluid level and top off to MAX line with fresh brake fluid meeting the specification stamped on the reservoir cap (typically DOT 3 for this vehicle) if needed.
    ⚠️Do not attempt to drive vehicle until brake pedal is firm and reaches proper height. Failure to restore pedal pressure will result in no rear braking.

Reassembly

1. Ensure all caliper slide pin bolts and bracket mounting bolts are properly tightened
2. Verify no brake hoses are twisted, kinked, or contacting suspension components through full range of motion
3. Double-check that brake fluid reservoir is filled to proper level with clean DOT 3 fluid
4. Verify wheel lug nuts are torqued properly in star pattern

Verification

• Start engine and pump brake pedal several times. Pedal should feel firm and consistent. If pedal feels soft or spongy, brake system may need bleeding
• With engine running, verify brake warning light is not illuminated on instrument cluster
• Perform low-speed test drive in safe area. Test brakes at 5-10 mph to verify even braking with no pulling to either side
• Perform proper break-in procedure: Make 30-40 gradual stops from 30-40 mph with light to moderate pedal pressure, allowing 30 seconds between stops for cooling. Avoid hard braking for first 300 miles
• After 50-100 miles, re-torque wheel lug nuts and verify no fluid leaks at calipers
• Listen for any unusual noises during braking. Slight noise initially is normal as pads seat, but grinding or squealing may indicate installation issues

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