TORQUE SPECIFICATIONS
| DESCRIPTION | N.m | Ft. Lbs. | In. Lbs. |
|---|---|---|---|
| Brake Booster Mounting Nuts | 28 | 21 | 250 |
| Master Cylinder Mounting Nuts | 18 | 160 | |
| Reservoir Retaining Screws | 8 | 6 | 71 |
| Caliper Bleed Screws | 19 | 14 | 169 |
| Caliper Mounting Pins, Front | 32 | 24 | |
| Caliper Mounting Pins, Rear | 30 | 22 | |
| Caliper Adapter Mounting Bolts, Front (1500) | 176 | 130 | |
| Caliper Adapter Mounting Bolts, Front (2500/3500) | 373 | 275 | |
| Caliper Adapter Mounting Bolts, Rear (1500) | 163 | 120 | |
| Caliper Adapter Mounting Bolts, Rear Upper (2500 and 3500) | 226 | 163 | |
| Caliper Adapter Mounting Bolts, Rear Lower (2500 and 3500) | 264 | 190 | |
| Junction Block Bolts, Front (1500) | 19 | 14 | 169 |
| Junction Block Bolts, Rear (1500) | 24 | 18 | 213 |
| Junction Block Bolts, Rear (2500/3500) | 10 | 7.5 | |
| Brake Pedal Assembly Bracket Bolts (1500) | 31 | 23 | |
| Brake Pedal Assembly Bracket Nuts (2500/3500) | 28 | 21 | |
| Support Plate Mounting Bolts/Nuts (1500) | 102 | 75 | |
| Support Plate Mounting Bolts/Nuts (2500/3500) | 203 | 150 | |
| Brake Line Fittings, Master Cylinder | 19 | 14 | 169 |
| Brake Line Fittings, Junction Block (Both) | 19 | 14 | 169 |
| Caliper Brake Line Banjo Bolt, Front | 27 | 20 | 245 |
| Caliper Brake Line Banjo Bolt, Rear | 28 | 20 | 245 |
| Brake Hose Bolts To Frame, Front | 10 | 7.5 | 89 |
| Brake Hose Fitting | 19 | 14 | 169 |
| Parking Brake Pedal Assembly (1500) | 25 | 18 | |
| Parking Brake Pedal Assembly (2500/3500) | 19 | 14 | |
| Hub/Bearing Bolts (1500) | 163 | 120 | |
| Rotor to Hub Bolt, Rear (2500 and 3500 DRW) | 154.5 | 114 | |
| Extension to Rotor Nut, Front (2500 and 3500 DRW) | 173.5 | 128 | |
| Hub/Bearing Bolts, Front (2500 and 3500 4X2) | 176 | 130 |
1500, 2500, 3500
| DESCRIPTION | Nm | Ft. Lbs. | In. Lbs. |
|---|---|---|---|
| Brake Booster Mounting Nuts | 28 | 21 | 250 |
| Master Cylinder Mounting Nuts | 18 | 160 | |
| Master Cylinder Mounting Nuts (4500 and 5500) | 37.5 | 28 | 332 |
| Reservoir Retaining Screws | 8 | 6 | 71 |
| Caliper Bleed Screws | 19 | 14 | 168 |
| Caliper Bleed Screws (4500 and 5500) | 12 | 9 | |
| Caliper Mounting Pins, Front (Cab Chassis) | 32 | 24 | |
| Caliper Mounting Pins, Front (4500 and 5500) | 133 | 98 | |
| Caliper Mounting Pins, Rear (Cab Chassis) | 30 | 22 | |
| Caliper Mounting Pins, Rear (4500 and 5500) | 133 | 98 | |
| Caliper Adapter Mounting Bolts, Front (Cab Chassis) | 373 | 275 | |
| Caliper Adapter Mounting Bolts, Front (4500 and 5500) | 530 | 400 | |
| Caliper Adapter Mounting Bolts, Rear Upper (Cab Chassis) | 226 | 163 | |
| Caliper Adapter Mounting Bolts, Rear Lower (Cab Chassis) | 264 | 190 | |
| Caliper Adapter Mounting Bolts, Rear Upper (4500 and 5500) | 465 | 343 | |
| Caliper Adapter Mounting Bolts, Rear Lower (4500 and 5500) | 530 | 400 | |
| Junction Block, Bolts To Frame | 10 | 7.5 | |
| Brake Hose Front Bolts to Axle (4500 and 5500) | 31 | 23 | 275 |
| Brake Pedal Assembly Bracket Nuts | 28 | 21 | |
| Support Plate Mounting Bolts/Nuts (Cab Chassis) | 203 | 150 | |
| Brake Line Fittings Master Cylinder | 19 | 14 | 170 |
| Brake Line Fittings, Junction Block | 19 | 14 | 170 |
| Caliper Brake Line Banjo Bolt | 28 | 21 | 250 |
| Brake Hose Bolts To Frame, Front (Cab Chassis) | 10 | 7.5 | |
| Brake Hose Bolts To Frame, Front (4500 and 5500) | 31 | 23 | 275 |
| Brake Hose Fitting, Front | 19 | 14 | 250 |
| Brake Hose/Tube, Rear (4500 and 5500) | 24 | 18 | 213 |
| Brake Hose Fitting, Rear | 19 | 14 | 250 |
| Brake Hose, Rear (4500 and 5500) | 24 | 18 | 213 |
| Brake Line Fitting, Rear (4500 and 5500) | 19 | 14 | 170 |
| Parking Brake Pedal Assembly | 19 | 14 | 250 |
| Parking Brake Pedal Assembly (4500 and 5500) | 28 | 21 | |
| Rotor to Hub Bolt, Rear (Cab Chassis DRW) | 154.5 | 114 | |
| Rotor to Hub Bolt, Rear (4500 and 5500 DRW) | 156 | 115 | |
| Extension to Rotor Nut, Front (Cab Chassis DRW) | 173.5 | 128 | |
| Extension to Rotor Nut, Front (4500 and 5500 DRW) | 176 | 130 | |
| Hub/Bearing Bolts, Front (Cab Chassis 4x2) | 176 | 130 | |
| Hub/Bearing Bolts, Front (4500 and 5500) | 200 | 147 |
3500 CAB CHASSIS, 4500, 5500
Scheme 1
Scheme 2
Scheme 3
- Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
- Remove the front wheel and tire assembly.
- Remove the caliper slide pin bolts (4). Refer to «CALIPER, Disc Brake , Removal»(ref-457773-S34405021932012030200000) . CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
- Remove the disc brake caliper (1) from the adapter (2).
- Remove the inboard (4) and outboard (2) brake pads.
- Remove the caliper adapter mounting bolts (5).
- Remove and transfer any necessary components.
Scheme 4
- Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
- Remove the wheel and tire assembly.
- Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun.
- Bottom the caliper pistons into the caliper by prying the caliper over.
- Remove the caliper slide bolts.
- Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
- Remove the inboard and outboard brake pads (1).
- Remove the anti-rattle clips (2).
- Remove the caliper adapter mounting bolts (4).
- Remove the caliper adapter.