Dakota, 2001-2005

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

  6.  
  7. Pry the piston side pad away from the rotor with a tool that won't scratch the rotor surface.
  8.  
  9. Remove the caliper bolts or pins.
  10.  
  11. Remove the caliper from the rotor.
    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.

  12.  

To install:

Click image to see an enlarged view

Fig. Clean the caliper contact slides with a wire brush



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Anytime the brake line is disconnected, new washers must be used to ensure a proper seal

  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. Install and tighten the caliper slide pins to 22 ft. lbs. (30 Nm).
    NOTE
    Start the bolts or pins by hand before tightening to avoid crossthreading.

  8.  
  9. Connect the brake line using new washers.
  10.  
  11. Bleed the caliper.
    CAUTION
    Bleeding of four-wheel antilock brake systems require the use of a dedicated scan tool.

  12.  
  13. Install the wheel.
  14.  
  15. Apply the brake several times to seat the pads before operating the vehicle.
  16.  
  17. Check the brake fluid level at the master cylinder reservoir and add if necessary.
  18.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise and support the front end on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Disconnect the rubber brake hose from the tubing at the frame mount. If the pistons are to be removed from the caliper, leave the brake hose connected to the caliper. Check the rubber hose for cracks or chafed spots.
  8.  
  9. Plug the brake line to prevent loss of fluid.
  10.  
  11. Remove the caliper slide pins.
  12.  
  13. Remove the caliper and brake pads from the rotor adapter.
  14.  

To install:

  1. Position the outboard shoe in the caliper. The shoe should not rattle in the caliper. If it does, or if any movement is obvious, bend the shoe tabs over the caliper to tighten the fit.
  2.  
  3. Slide the caliper into position on the adapter and over the rotor.
  4.  
  5. Align the caliper and start the pins in by hand.
  6.  
  7. Tighten the pins to 22 ft. lbs. (30 Nm).
  8.  
  9. Connect the brake hose to the caliper. Use new washers to attach the hose fitting if the original washers are scored, worn or damaged.
  10.  
  11. Fill and bleed the brake system.
  12.  
  13. Install the wheels.
  14.  
  15. Lower the vehicle.

    Click image to see an enlarged view

    Fig. 2002-04 front caliper removed

  16.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    CAUTION
    Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely.

  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Compress the disc brake caliper.
  8.  
  9. Remove the banjo bolt and discard the copper washers.
  10.  
  11. Remove the caliper slide pin bolts.
  12.  
  13. Remove the disc brake caliper from the caliper adapter.
  14.  
  15. Remove the caliper slide pins from the adapter.

    Click image to see an enlarged view

    Fig. (1) caliper mounting adaptor, (2) caliper mounting bolts, (3) brake line, (4) banjo bolt, (5) pad, (6) caliper-2005 models

  16.  

To install:


WARNING
Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease.


NOTE
Clean slide pin bores thoroughly to remove any old grease.


NOTE
Use grease packets included with kit or Dow Corning-807T grease.

  1. Thoroughly coat the new slide pins on all working surfaces.
  2.  
  3. Install the boot onto the slide pin and then insert into the adapter.
  4.  
  5. Push the pin all the way into the adapter and carefully expel the trapped air by gently pushing on the boot near the slide pin head.
    NOTE
    Install a new copper washers on the banjo bolt when installing

  6.  
  7. Install the disc brake caliper to the brake caliper adapter.
  8.  
  9. Install the banjo bolt with new copper washers to the caliper. Tighten to 28 Nm (250 inch lbs.)
  10.  
  11. Install the caliper slide pin bolts. Tighten to 32 Nm (24 ft. lbs.).
  12.  
  13. Bleed the base brake system.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  

 
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