Chrysler Full-Size Trucks 1997-2000 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Disconnect the brake line from the caliper if the unit is to be removed from the vehicle. Plug the end of the brake line. Be sure to use new washers on installation. Disconnecting the line will require bleeding of the system.
  6.  


CAUTION
Bleeding of four-wheel antilock brake systems require the use a dedicated scan tool. Lines should not be disconnected unless one is available.

  1. Pry the piston side pad away from the rotor with a tool which won't scratch the rotor surface.
  2.  
  3. Remove the caliper bolts or pins.
  4.  
  5. Remove the caliper from the rotor.
  6.  


NOTE
Do NOT apply the brake pedal with the caliper off the rotor. Use a soft wedge (such as a piece of wood) to hold the pads apart if the caliper is to be off the rotor for any length of time.

To install:

  1. Clean the caliper slide surfaces with a wire brush where applicable. Then lubricate the surfaces with a thin coat of high temperature grease.
  2.  
  3. Push the piston(s) in far enough to allow the pads to clear the rotor. This can be done by hand or with a special tool: several types are available.
  4.  
  5. Install the caliper on the rotor.
  6.  
  7. Dakota, Durango: install and tighten the caliper slide pins to 22 ft. lbs. (30 Nm).
  8.  
  9. Ram: tighten the caliper bolts to 38 ft. lbs. (51 Nm) on 1997-99 models; tighten to 24 ft. lbs. (33 Nm) on 2000 models.
  10.  


NOTE
Start the bolts or pins by hand before tightening to avoid crossthreading.

  1. Connect the brake line using new washers.
  2.  
  3. Bleed the caliper.
  4.  


CAUTION
Bleeding of four-wheel antilock brake systems require the use a dedicated scan tool.

  1. Install the wheel.
  2.  
  3. Apply the brake several times to seat the pads before operating the vehicle.
  4.  
  5. Check the brake fluid level at the master cylinder reservoir and add if necessary.
  6.  



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Fig. Clean the caliper contact slides with a wire brush



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Fig. Lubricate the caliper slides with a good grade of grease after cleaning

OVERHAUL




NOTE
Read the "Brake Hoses And Lines" section for useful hints and tips on brake line work.


NOTE
Late model Rams are equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This will result in personal injury!


NOTE
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Keep pressure low! It doesn't take more than a few psi in a short burst to move the piston!
    4.  

  2.  
  3. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
  4.  



Click image to see an enlarged view

Fig. Use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



Click image to see an enlarged view

Fig. Withdraw the piston from the caliper bore

  1. If equipped, remove the anti-rattle clip.
  2.  



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Fig. On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



Click image to see an enlarged view

Fig. Use a prytool to carefully pry around the edge of the boot . . .



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Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:

  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



Click image to see an enlarged view

Fig. Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Properly bleed the brake system.
  4.  


CAUTION
Bleeding of four-wheel antilock brake systems require the use a dedicated scan tool. Lines should not be disconnected unless one is available.

  1. Install the wheel, then carefully lower the vehicle
  2.  

 
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