How to Remove Brake Rotors From a 2004 Dodge Ram

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The Dodge Ram has endured many years and many generations in the Chrysler Corporation. In 2004, the Ram was available in 1/2-ton, 3/4-ton and 1-ton models. Available engine sizes ranged from a 3.7-liter 6-cylinder--available in the 1/2-ton series--to a 10-cylinder. The 3/4-ton and 1-ton models offered a 5.9-liter diesel engine or the infamous 5.7-liter Hemi engine, which was available in the 1/2-ton as well. While removing the brake rotors was basically the same for the 1/2-ton and 3/4 ton Rams, the 1-ton version added a slightly different procedure.

Things You'll Need

  • Vehicle lift or truck lift
  • 1/2-inch-drive impact gun
  • 1/2-inch-drive impact socket set
  • Caliper hook or metal hanger
  • Pry tool
  • Wrench set
  • Hammer
  • Three-pronged hub and rotor puller
  • Die-grinder and coarse reconditioning discs
  • Lift the Dodge Ram on a vehicle or truck lift to a suitable height to work on.

  • Remove the lug nuts using an impact gun and a 7/8-inch impact socket or a 22 mm impact socket. Remove the center cap--secured by the tapered lug nuts--and then remove the wheel.

  • Disconnect the two caliper bolts using a hand wrench. Pry the caliper and pad assembly off the rotor and support it to the suspension using a caliper hook or metal hanger.

  • Remove the caliper adapter bolts using the impact gun and a suitable socket. Remove the adapter.

  • Remove the rotor from the wheel hub assembly. This task may require cutting off rotor retaining clips from two of the lug studs if applicable. Removing the rotor may also require a variation of different procedures. If the rotor wiggles and moves, it will be able to be pulled off without incident. If it is stuck to the hub due to rust and corrosion, the reason it is being removed will have to be considered. If it's being removed and then reused, the rotor will have to be delicately removed with a three-pronged hub and rotor puller. If it is being removed for replacement, you can knock it off with a hammer, striking the flat plate on the edges of the rotor until it breaks free from the hub.

  • Clean the surface of the hub facing and edges with a die-grinder and a coarse reconditioning disc before replacing the rotor.

Tips & Warnings

  • The caliper piston will need to be retracted before replacing the caliper. This can be done with a large C-clamp or caliper piston tool. On 1-ton models, the hub extension mounting nuts will need to be removed and then the hub extension before removing the caliper assembly. This can be done with the impact gun and a suitable socket or a ratchet and socket set.
  • Be sure to pump the brake pedal once the Ram is back together to restore the compressed caliper piston to its seated position. Otherwise there will be no braking response until the pistons extend outward from the caliper piston bore. This, however, can cause a serious accident if there are any nearby obstacles.

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