How to Remove a Rear Brake Rotor From a 2002 Dodge Ram

Dodge began using a rams head emblem on the hood of its trucks in 1933 as a symbol of the toughness and rugged nature of their pickups. In the 1950s, this emblem disappeared and remained dormant for nearly three decades. Upon the release of its new line of Ram pickups in 1981, Dodge dusted off the old rams head emblem for the new truck's hood. The 2002 Ram 1500 came standard with four-wheel disc brakes that included ventilated front rotors and solid rear rotors. Replacing the solid rear rotors is a straightforward task, thanks to Dodge making the parking brake system an independent assembly from the caliper.

Instructions

Loosen the rear lug nuts with a ratchet and socket. Raise the rear of the Ram with a floor jack and position jack stands under the rear axle tubes, roughly 12 inches in from the rear wheels. Lower the truck onto the jack stands. Remove the lug nuts and pull the rear wheels off.

Set a drain pan under the rear caliper. Position an 8-inch C-clamp over the caliper, so its fixed clamp pad contacts the rear of the caliper and its clamp bolt contacts the rear of the outer brake pad. Loosen the bleeder valve the quarter-inch metal valve on the rear of the caliper with a combination wrench, then immediately tighten the C-clamp until it stops moving. Immediately close the bleeder valve with a combination wrench. Remove the C-clamp and wipe away any spilled brake fluid with a shop rag.

Remove the two caliper guide pins with a ratchet and socket. Pull the caliper from its bracket, then hang it from a nearby suspension component using a bungee strap.

Pull the brake pads and pad slippers, the thin metal shims above and below the pads, from the caliper bracket. Remove the two bolts securing the caliper bracket, using a ratchet and socket, and remove the caliper bracket.

Pull the locking washers off the wheel studs with needle-nose pliers. Discard these clips, as they are needed only for initial assembly of the truck. Pull the rotor off the rear hub with a slight wiggling motion. If the rotor is stuck, lightly strike the rear of it with a rubber mallet to free it. Use caution not to disturb the parking brake shoes as you remove the rotor.

Repeat steps 2 through 5 to remove the rotor on the other side of the Ram.

Slide the new rotor onto the rear hub. Set the caliper bracket into place on the rear hub and hand-thread its retaining bolts. Torque these bolts to 100 foot-pounds with a torque wrench and socket.

Press new pad slippers, which are included with the new brake pads, into their cutouts in the caliper bracket. The slippers are asymmetrical, so you can only install them facing in one direction. Slide new brake pads into the caliper bracket. Remove the caliper from the bungee strap and set it on the caliper bracket.

Clean the old grease and dirt off the caliper guide pins with a clean, lint-free cloth. Apply a thin coat of new disc brake grease to the smooth part of each guide pin. Insert the guide pins and hand-thread them. Torque the caliper guide pins to 22 foot-pounds.

Repeat steps 1 through 3 to install the rotor on the other side of the vehicle.

Reinstall the wheels onto the rear hubs and hand-thread the lug nuts. Raise the truck off the jack stands using a floor jack; remove the jack stands. Lower the Ram to the ground. Torque the lug nuts, in a crisscross pattern, to 135 foot-pounds.

Press and release the brake pedal until it feels firm. Check the brake fluid level in the master cylinder reservoir. If the fluid level is not at the Max line, unscrew the reservoirs cap and add new DOT 3 brake fluid until the level reaches the Max line.

Take the old brake fluid in the drain pan to a used automotive recycling center. Some auto parts stores take old fluids free of charge.