The Dodge Durango was very common to warp from brake rotors. A heavy front-end vehicle powered by a large 4.7-liter, 8-cylinder engine, the front brake took on over 80 percent of the braking capacity for the popular SUV. This resulted in heating up the front rotors and in many cases created an excessive runout or warping of the rotor. Although the sound of having to do your own brake work sounds intimidating to many people, replacing the rotors on the Dodge Durango is not overly complicated. With a little technical savvy and a small variety of automotive repair tools in your garage, you can save a lot of money on labor.
M/F Park the Durango on a flat, level, paved or concrete surface. Place it in gear or "Park" and apply the parking brake. Place a wheel chock behind one rear tire and break the lug nuts loose on the left front tire using the 1/2-inch breaking bar and socket.
M/F Lift the left front quarter with the floor jack and support the Durango on a jack stand in a safe and secure manner. Remove the lug nuts and remove the wheel.
M/F Remove the brake caliper bolts using the ratchet and a socket. Place the caliper on top of the upper control arm. Do not let it dangle from the brake hose.
M/F Remove the inboard pad and outboard pad using the straight edged screwdriver, and note how they were removed so you can replace them exactly the same way you took them off.
M/F Remove the retainers on the rotor if present. Rotors from the manufacturer may have a small metal retainer clip on one or two of the lug studs. If so, pry them away from the hub of the rotor with the screwdriver and then pull them off with the pliers. Don't worry about damaging them because you don't need to replace them. If the rotor loosens when you remove the retainer clip(s), take it off the hub and skip the next step.
M/F Strike the fins of the rotor with a hammer to shock it from the hub. Corrosion and rust sometimes build up in and on the center of the hub and seize the rotor to the hub. Striking the fins of the rotor with a hammer, being careful not to hit the fender or other components, may be necessary to loosen the rotor from the hub.
M/F Clean the new rotor using brake clean spray to remove anti-rust coating on the front and back of the new rotor.
M/F Squeeze in the piston of the caliper using a C-clamp.
M/F Place the pads appropriately into the caliper adapter while holding the rotor flush against the hub.
M/F Place the caliper over the pads and rotor. Replace the caliper bolts and tighten them.
M/F Replace the wheel and lug nuts. Tighten the lug nuts and then re-tighten them when the vehicle is lowered to the ground, using a 1/2-inch, drive-adjustable torque wrench set to 100 foot pounds and a socket.
M/F Pump the foot brake pedal in the Durango when finished to restore the hydraulic pressure to the pistons of the calipers. Failure to perform this step could result in hazardous or fatal conditions when test driving.
M/F Check and adjust the level of the brake fluid in the master cylinder.
M/F Remove the wheel chock and go for a test drive.