OEM 2002 Dodge Ram 2500 Van Brake Caliper

2002 Dodge Ram 2500 Van Brake Caliper Parts and Q&A

• Q: How to service and repair disc brake calipers on 2002 Dodge Ram 2500 Van?

  A: Before you service or repair disc brake calipers, lift the vehicle, support it and remove the front wheel and tire. First, remove the caliper brake hose bolt, two washers and hose, then take out the caliper mounting bolts. Raise the bottom of the caliper to get it off the adapter and carefully remove the anti-rattle springs, remembering you cannot mix the springs from bottom and top. Pump the brake fluid from the caliper and then clamp a block of wood over one piston equipped with a C-clamp to keep it safe. Lay a padded piece of wood in front of the other piston so it doesn't get damaged while being removed. Use a few short even breaths into the caliper brake hose port to move the first piston out so as not to apply pressure long enough to damage it. After removing the first piston, place the C-clamp over the empty bore and a wooden block beneath it and repeat for the second piston. Lift off the piston dust boots and gently remove the piston seals, making sure you don't scratch the bores. Get rid of both the caliper mounting bolt bushings and the bleed screw. Always use clean brake fluid or brake cleaner to wipe clean the different caliper parts. Look over the piston carefully; if it is cracked or marked, replace it with the same type, because steel and phenolic resin pistons cannot be used interchangeably. Should light polishing not be enough, use a brake hone; otherwise, replace the caliper if the caliper's bore is excessively corroded or is widened more than 0.025 mm (0.001 inch) by polishing. Before installing, ensure the brakes are in a clean, dry spot, add lubricant to the pistons and seals and seal the new piston seals into place. Rub silicone grease gently around the new boot's lip, put it on the piston and press it down firmly. Put the piston into the caliper bore and then seat the dust boot with the installer tool. Apply brake grease to the caliper's bolts, the bushings, the boot seals and the bores, then put in the boot seals and bushings and engage the seal lip. Once you've cleared the system, return the caliper bleed screw to its proper place. When installing the upgrade, wipe the caliper mounting adapter, apply oil to the anti-rattle springs and mount the springs on the caliper. Move the caliper so it is over the rotor and under the adapter and slide it onto the adapter. Turn the screws holding the caliper in place to 33 Nm (24 ft. lbs.) and socket wrench the brake hose connection, tightening it to 24 Nm (18 ft. lbs.) as you avoid any twists or bends in the hose. Blow out the brake system, put back the wheel and tire assemblies, take down the supports, bring down the car and test that the pedal feels strong before moving the car.