Tools You'll Need:
* Jack and jack stands
* Lug wrench
* Wheel chocks
* Socket wrench and sockets (various sizes, likely including 13mm, 15mm, 18mm and possibly others)
* Wrench for caliper bolts (likely 14mm or 15mm – check your manual)
* C-clamp or brake caliper compression tool
* Hammer (optional, for stubborn rotors)
* Penetrating oil (like PB Blaster)
* Gloves and safety glasses
Procedure:
1. Safety First: Park the truck on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands to securely lift the front of the truck. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Expose the Brake Caliper: You'll see the brake caliper assembly clamped onto the rotor.
4. Compress the Caliper Piston: You need to retract the caliper piston to create enough space to remove the rotor. There are two ways to do this:
* C-clamp method: Carefully use a C-clamp to compress the caliper piston back into the caliper. Go slowly and steadily to avoid damaging the piston seal. You may need to rotate the piston as you compress it.
* Brake caliper compression tool: This specialized tool is designed for this purpose and makes the job easier and less risky.
5. Remove the Caliper: Once the piston is compressed, you'll likely need to unbolt the caliper. There are usually two bolts holding the caliper to the caliper bracket. Carefully remove these bolts and support the caliper with a bungee cord or wire to prevent it from hanging by the brake line. Do not let the brake line hang freely.
6. Remove the Rotor: The rotor should now be free to slide off the wheel studs. Sometimes they can stick a little due to rust or corrosion. If it's stuck, you might need to gently tap it with a hammer (protect the rotor's surface with a soft cloth or block of wood) while applying some light force to remove it. Avoid damaging the wheel studs.
7. Clean Up: Clean any rust or debris from the wheel studs and the hub.
8. Installation (Reverse Order): Installation is the reverse of removal. Remember to lubricate the caliper slide pins before reinstalling the caliper. Make sure the caliper slides freely. Torque all bolts to the manufacturer's specifications in your repair manual.
9. Bleed the Brakes (Important): After reinstalling the caliper, you might need to bleed the brakes to remove any air that may have entered the system during the process. Consult your owner's manual or a repair guide for bleeding procedures. This step is crucial for proper braking performance.
Important Considerations:
* Rust: If the rotor is severely rusted, it might be difficult to remove. Use a penetrating oil like PB Blaster and let it sit for some time before attempting removal.
* Caliper Slide Pins: Lubricate the caliper slide pins with appropriate lubricant. This ensures the caliper moves freely and prevents uneven brake pad wear.
* Torque Specifications: Always consult your repair manual for the proper torque specifications for all bolts. Over-tightening can cause damage, while under-tightening can lead to loosening and failure.
* Brake Pad Wear: Inspect your brake pads while the caliper is removed. Replace them if necessary.
This guide provides a general overview. It's strongly recommended to consult your vehicle's repair manual for detailed instructions and specific torque specifications relevant to your 1999 Dodge Ram 2500. If you are uncomfortable performing this task, it is best to take it to a qualified mechanic.
