How to Install Brakes on a Dodge Ram 2500

The brake assembly on a Dodge Ram 2500 full-size truck is comprised of multiple parts. The brake pads are within the caliper, which is mounted on a bracket connected to the brake disc that is installed on the axle rotor. If you need to install any parts on the brake assembly, it goes in this order: Brake disc, hub and bearing assembly, caliper mounting bracket and caliper with brake pads installed within. If you are immediately replacing any parts, you must remove the old ones first.

Instructions

1

Raise and support one full end of the Ram truck on jack stands - either the front or rear end. Make sure the parking brake is applied and remove the wheels. Loosening the lug nuts before raising the truck will make wheel removal easier.

2

Install a brake disc on the rotor that has been smoothly finished, making sure it is at least as thick as the minimum thickness that is cast along the edge of the disc. Measure this thickness with a micrometer, wipe any glaze off the disc with sandpaper or an emory cloth and then bolt the disc to the hub.

3

Connect the hub and bearing assembly to the disc. Insert the axle shaft into the axle housing and attach the brake dust shield to the steering knuckle. Place the hub bearing on the steering knuckle and axle shaft and tighten the bearing-to-knuckle bolts to 125 foot-pounds. Install the axleshaft washer and nut to 263 foot-pounds, line the nut up with the next cotter pin hole and install a cotter pin in that hole

4

Attach the caliper mounting bracket to the disc, tightening its retaining bolts to 250 foot-pounds for front brakes and 145 for rear brakes. If the Ram is older than a 2005 model, tighten the front bracket bolts to 210 foot pounds.

5

Insert fresh brake pads into the brake caliper, starting with the inner pads and then the outer ones, making sure the pads are seated in their grooves and retaining clips. If the caliper piston isn't completely within its bore, compress it with a C-clamp before installing the pads.

6

Place the caliper on its mounting bracket and tighten its bolts to 24 foot-pounds for front brakes and 22 for rear brakes (on a Ram 2500 older than 2005, tighten the rear caliper bolts to 24 foot-pounds). Connect the brake hose to the caliper and tighten the banjo bolt to 30 foot pounds.

7

Fill the brake master cylinder with brake fluid after all new brakes are installed and bleed the system. Loosen the caliper's bleeder screw, place a length of clear tubing on the screw fitting, and place the tube's other end in a container of fluid. Open the bleeder screw while another person presses the brake pedal until no more air bubbles leave the system.