2005 Dodge RAM 3500 Front Disc Brake Caliper Replacement.pdf

2005 Dodge RAM 3500 Front Disc Brake Caliper Replacement

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Calipers-disc brake front removal caution: never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. 2. 3. 4. 5. Raise and support the vehicle. Remove the tire and wheel assembly. Compress the disc brake caliper. Remove the banjo bolt and discard the copper washer. Remove the caliper slide bolts. 6. Remove the disc brake caliper (2). Disassembly disc brake caliper 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston.

This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. Caution: do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Warning: never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the c-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. Caution: do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1).