Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Brake Caliper

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  6.  
  7. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  8.  
  9. Loosen the bolt that secures the front brake hose fitting bolt in the caliper.
  10.  
  11. Rotate the caliper rearward off the rotor and out from its mount.

    Click image to see an enlarged view

    Fig. Mounting bolt lubrication points-Ram Pick-Up 75mm caliper

    Mounting bolt lubrication points-Ram Pick-Up 75mm caliper

    Click image to see an enlarged view

    Fig. Mounting bolt lubrication points-Ram Pick-Up 80 or 86mm caliper

    Mounting bolt lubrication points-Ram Pick-Up 80 or 86mm caliper
  12.  
  13. Remove the front brake hose fitting bolt completely, then remove the caliper with the pads installed as an assembly. Take care not to drip fluid onto the pad surfaces.
  14.  
  15. Cover the open end of the front brake hose fitting to prevent dirt entry.
  16.  

To install:

  1. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease or equivalent.
  2.  
  3. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111® or GE 661® silicone grease or equivalent.
  4.  
  5. Install the caliper over the rotor and seat it in its original position until flush.
  6.  
  7. Install the mounting bolts by hand, then tighten them to 38 ft. lbs. (51 Nm) on 2001-02 models; 24 ft. lbs. (32 Nm) on 2003-05 models.
  8.  
  9. Attach the brake hose, using new washers, and torque the bolt to 20 ft. lbs. (27 Nm).
  10.  
  11. Install the wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Pump the brakes several times to seat the pads.
  16.  

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  6.  
  7. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  8.  
  9. Loosen the bolt that secures the front brake hose fitting bolt in the caliper.
  10.  
  11. Rotate the caliper rearward off the rotor and out from its mount.
  12.  
  13. Remove the front brake hose fitting bolt completely, then remove the caliper with the pads installed as an assembly. Take care not to drip fluid onto the pad surfaces.
  14.  
  15. Cover the open end of the front brake hose fitting to prevent dirt entry.
  16.  

To install:

  1. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease or equivalent.
  2.  
  3. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111® or GE 661® silicone grease or equivalent.
  4.  
  5. Install the caliper over the rotor and seat it in its original position until flush.
  6.  
  7. Install the mounting bolts by hand, then tighten them to 24 ft. lbs. (38 Nm).
  8.  
  9. Install the wheels.
  10.  
  11. Lower the vehicle.
  12.  
  13. Pump the brakes several times to seat the pads.
  14.  

 
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