Brake Rotor - Rear Single

This procedure covers removal and replacement of a single rear brake rotor on a 2007 Ram 3500 with 5.9L Cummins diesel and 4WD.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification or quality aftermarket equivalent

Preparation

1. Park vehicle on a level, paved surface and set parking brake
2. Place wheel chocks in front of both front wheels
3. Loosen the rear wheel lug nuts 1/4 turn before lifting (do not remove)
4. Lift the rear corner of the vehicle using the axle housing as the lift point
5. Support vehicle with heavy-duty jack stand placed under the frame rail
6. Remove the wheel lug nuts and remove the wheel
7. Inspect the brake system for any leaks, damaged lines, or worn components

Procedure

1. 1

   Compress brake caliper piston
   Before removing the caliper, slowly compress the caliper piston back into its bore using a large C-clamp or brake caliper compression tool. Place the clamp against the back of the caliper body and against the outer brake pad. This prevents fluid overflow and makes caliper removal easier. Compress slowly and evenly.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear side of the caliper (facing the differential). Use an 18mm socket or wrench to remove both slide pin bolts completely. If bolts are seized, apply penetrating oil and allow to soak for 10-15 minutes. Keep these bolts organized as they will be reused.
3. 3

   Remove and support brake caliper
   Carefully lift the caliper assembly straight up and off the rotor. The brake pads may come with it or stay on the caliper bracket. Do NOT let the caliper hang by the brake hose. Use wire or a bungee cord to hang the caliper from the suspension or frame above. Ensure no tension is placed on the rubber brake line.
4. 4

   Remove brake pads and clips
   Remove the brake pads from the caliper bracket if they did not come off with the caliper. Note their orientation for reassembly. Remove the anti-rattle clips from the caliper bracket and set aside for cleaning and reinstallation.
5. 5

   Remove caliper bracket
   Remove the two caliper bracket mounting bolts using the correct socket size (verify with service manual) and breaker bar. These bolts are torqued very tight. The bracket will then slide off the caliper anchor/knuckle. Note: On Ram 3500 DRW (dual rear wheel) models, access may be more difficult.
6. 6

   Remove brake rotor
   Pull the rotor straight off the wheel hub. If the rotor is stuck due to corrosion, tap it from behind with a rubber mallet while rotating it. Do NOT strike the rotor face. If severely corroded, spray penetrating oil around the hub-to-rotor interface and wait 15 minutes. Some rotors may have threaded holes for bolts to aid removal by forcing the rotor off the hub.
7. 7

   Clean hub surface
   Use a wire brush to thoroughly clean the hub mounting surface where the rotor sits. Remove all rust, corrosion, and debris. The hub face must be clean and flat for proper rotor seating. Clean the wheel studs with a wire brush. Apply a thin layer of anti-seize compound to the hub face (not the braking surfaces).
8. 8

   Install new brake rotor
   Place the new rotor onto the hub, aligning it with the wheel studs. Ensure the rotor sits completely flat against the hub surface with no gaps. Thread on one lug nut temporarily to hold the rotor in place during reassembly. Clean any protective coating from the new rotor using brake parts cleaner on both friction surfaces.
9. 9

   Reinstall caliper bracket
   Slide the caliper bracket over the wheel studs and align the mounting holes. Install both bracket mounting bolts and tighten evenly. NOTE: Torque specifications are not available in the database. Consult a factory service manual for proper torque values for these caliper bracket/anchor bolts before tightening. Apply medium-strength thread locker to bolt threads before installation.
10. 10

    Reinstall brake pads and hardware
    Clean the caliper bracket and anti-rattle clips with brake cleaner. Reinstall the clips into the bracket. Install the brake pads into the bracket in their correct orientation (wear indicators facing downward/inward). Ensure pads move freely in the bracket.
11. 11

    Reinstall brake caliper
    Remove the support wire from the caliper. Position the caliper over the brake pads and rotor, aligning the slide pin bolt holes. Install both slide pin bolts and tighten. NOTE: Torque specifications are not available in the database. Consult a factory service manual, typically 22-30 ft-lbs. Do not overtighten as this can bind the caliper.
12. 12

    Reinstall wheel and lower vehicle
    Remove the temporary lug nut holding the rotor. Reinstall the wheel onto the hub, aligning all lug nut holes. Install all lug nuts by hand, threading them clockwise. Snug the lug nuts in a star pattern with a wrench. Lower the vehicle until the tire just touches the ground. Torque the lug nuts to manufacturer specification (verify exact value in factory service manual — HD Ram 3500 lug torque is significantly higher than light-duty trucks) in a star pattern. Fully lower vehicle and remove jack stand.

Reassembly

1. Ensure all caliper bolts and bracket bolts are properly torqued per factory specifications
2. Verify the caliper moves freely on its slide pins
3. Confirm the brake hose has no kinks, damage, or tension

Verification

• CRITICAL: Before moving the vehicle, pump the brake pedal several times until it feels firm. The first few pumps will move the caliper pistons back against the new rotor
• Check brake fluid level in the master cylinder reservoir and top off with DOT 3 brake fluid if needed (do not overfill)
• Start the engine and test brake pedal feel. Pedal should be firm, not spongy
• Perform a low-speed brake test in a safe area. Brakes should apply smoothly without pulling to one side
• Listen for any unusual noises during initial brake applications (slight squeaking during break-in is normal)
• After driving 50-100 miles, re-torque wheel lug nuts to specification
• New rotors and pads require a break-in period. Avoid hard braking for the first 200 miles to allow proper bedding

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