Ram B1500, B2500, B3500, 1999-2003

Brake Disc (Rotor)

Print

Removal & Installation



  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the caliper from the steering knuckle, and remove caliper adapter assembly.
    NOTE
    Do not allow brake hose to support caliper adapter assembly.

  6.  
  7. Remove the rotor from the hub/bearing wheel studs.
  8.  

To install:


NOTE
On models with all-wheel Anti-lock Brake System (ABS), check condition of tone wheel on hub/bearing. If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately).

  1. Install rotor onto the hub/bearing wheel studs.
  2.  
  3. Install the caliper adapter assembly. Tighten the adapter bolts to:
    1. LD 1500: 130 ft. lbs. (176 Nm)
    2.  
    3. HD 2500: 210 ft. lbs. (285 Nm)
    4.  

  4.  
  5. Install the wheel and tire assembly and lower vehicle.
  6.  
  7. Apply brakes several times to seat brake shoes. Be sure to obtain firm pedal before moving vehicle.
  8.  

  1. Raise and support vehicle.
  2.  
  3. Remove wheel and tire assembly.
  4.  
  5. Remove caliper.
    NOTE
    Do not allow brake hose to support caliper assembly.

  6.  
  7. Remove caliper adapter bolts from the steering knuckle and remove adapter.
  8.  
  9. Remove grease cap, cotter pin, nut lock, nut, washer and outer wheel bearing.
  10.  
  11. Remove the rotor from the spindle.

    Click image to see an enlarged view

    Fig. Exploded view of the front brake rotor and related components

  12.  

To install:

  1. Inspect and repack wheel bearings if necessary. Install new grease seals if inner bearing was removed. On models with Anti-lock Braking System (ABS), check condition of tone wheel in rotor hub. If teeth on wheel are damaged, rotor and hub assembly will have to be replaced (tone wheel is not serviced separately).
  2.  
  3. Carefully slide the hub/rotor onto the spindle. Install outer wheel bearing, washer and retaining nut. Tighten the nut to 30-40 ft. lbs. (41-54 Nm) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin.
    NOTE
    The end play should be 0.001-0.003 in. (0.25-0.076mm).

  4.  
  5. Clean grease cap and coat interior of cap with wheel bearing grease, then install cap.
  6.  
  7. Install caliper adapter and tighten adapter bolts to:
    1. LD 1500: 130 ft. lbs. (176 Nm)
    2.  
    3. HD 2500/3500: 210 ft. lbs. (285 Nm)
    4.  

  8.  
  9. Install caliper and tighten bolts to 24 ft. lbs. (33 Nm).
  10.  
  11. Install wheel and tire assembly and lower vehicle.
  12.  
  13. Apply brakes several times to seat brake shoes. Be sure to obtain firm pedal before moving vehicle.
  14.  

5-Stud Rotor
  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the retainers on the wheel studs and remove the rotor. If stuck, the rotor can be freed with a light duty puller or a plastic mallet. Do NOT use excessive force.
  8.  
  9. Installation is the reverse of removal.
  10.  



Click image to see an enlarged view

Fig. Brake rotor and hub assembly-Dakota shown



Click image to see an enlarged view

Fig. Removing a rotor retainer



Click image to see an enlarged view

Fig. Balky rotors can be freed with a light-duty puller...



Click image to see an enlarged view

Fig. ...or a plastic mallet wielded with care

8-Stud Rotor
  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the hub extension.
  6.  
  7. Remove the brake caliper assembly.
  8.  
  9. Remove the axle nut cotter pin. Remove the axle nut.
  10.  
  11. Disconnect the ABS wheel speed sensor wire from under the hood. Remove the sensor wire from the frame and steering knuckle, if equipped.
  12.  
  13. Back off the hub/bearing mounting bolts 1 / 4 inch each. Then tap the bolts with a hammer to loosen the hub/bearing mounting bolts.
  14.  
  15. Remove the bolts and remove the hub/bearing assembly.
  16.  
  17. Installation is the reverse of removal. Observe all tightening torques as found in the specifications charts. Use a new cotter pin and apply anti-seize compound to the axle splines.
  18.  



Click image to see an enlarged view

Fig. Rotor and hub/bearing-Ram with 8-Stud Rotor

 
label.common.footer.alt.autozoneLogo